Troubleshooting P&H 1301

ELECTROTORQUE® TROUBLESHOOTING GUIDE
MODELS 2300XPB, 2800XPB, 4100, & 4100A
CAT 305-2
JUNE 15, 1998
TC CAT 305-2 VER 00, 06-98

PREFACE
This manual is provided as a guide to personnel involved with the electrical maintenance and repair of this mining shovel. We
recommend that such personnel review and become familiar with the general procedures and information contained within this
manual. In addition, we recommend that this manual be kept readily available for reference when repairs or maintenance are
necessary.
Due to the complexities of this mining shovel and the environment in which it operates, situations may arise which are not directly
discussed in detail in this manual. When such a situation arises, past experience, availability of equipment, and common sense play
a large part in what steps are to be taken. In addition, a P&H representative is available to answer your questions and assist you upon
request.
Please feel free to contact a P&H representative at any of the following locations to assist you as requested.
Copyright
Under the copyright laws, this documentation may not be copied, photocopied, reproduced, translated, or reduced
to any electronic medium or machine readable form, in whole or part, without the prior written consent of the
Harnischfeger Corporation.
© Copyright August 10, 1998 11:11 am, Harnischfeger Corporation, Milwaukee, Wisconsin, USA
All rights reserved. Printed in the United States.
vii
Table of Contents
Section 1 …………… General Information

Section 2 …………… Controls
Section 3 …………… Meter Module Operation
Section 4 …………… Trouble Shooting with the PLC-5/1 Fault
Indicators
Section 5 …………… Trouble Shooting Non-Indicating Faults
Section 6 …………… Control Frame and Component Testing
Section 7 …………… RPC Systems
Section 8 …………… Diverter Section
Section 9 …………… Auxiliary Systems
Section 10 ………….. Instrument Operation
Section 11 ………….. PLC Lubrication Control
Section 12 ………….. Proper Mounting and Testing of Power Semi-
Conductors
List of Figures
Common Electrical Symbols .....................................................................................................................1-3
Common Electrical Symbols (Continued) .................................................................................................1-4
Simple Logic Symbols ...............................................................................................................................1-5
Simple Logic Symbols (Continued) ..........................................................................................................1-5
Bistable Element (Memory Element) ........................................................................................................1-5
Bistable Element (Continued) ....................................................................................................................1-6
Monostable Elements .................................................................................................................................1-6
Astable Elements .......................................................................................................................................1-6
Delay Elements ..........................................................................................................................................1-6
Level Discriminator ...................................................................................................................................1-7
Amplifier Circuits ......................................................................................................................................1-7
Amplifier Circuits (Continued) ..................................................................................................................1-7
Amplifier Circuits (Continued) ..................................................................................................................1-8
Other Symbols ...........................................................................................................................................1-8
Model 2300XPB Equipment Locations .....................................................................................................1-9
Model 2800XPB and 4100 Equipment Locations ...................................................................................1-10
Model 4100A Equipment Locations ........................................................................................................1-11
Operator Control Locations - Model 4100 ................................................................................................2-3
Operator’s Controls - Raised Control Console Panels ...............................................................................2-7
Meter Module ............................................................................................................................................3-1
Meter Selector ............................................................................................................................................3-2
Test Selector ..............................................................................................................................................3-2
Field Current Meter ...................................................................................................................................3-3
Armature Current Meter ............................................................................................................................3-3
Armature and Control Voltage Meter ........................................................................................................3-3
Test Jack ....................................................................................................................................................3-4
PLC-5 Processor Module ...........................................................................................................................4-4
Inserting a Memory Module ......................................................................................................................4-7
Control Frames ..........................................................................................................................................6-1
Hoist Field Control Frame .........................................................................................................................6-2
Hoist Field Pulse Generator Output Waveform .........................................................................................6-3
Pulse Amplifier Output ..............................................................................................................................6-3
Thyristor Firing Pulse ................................................................................................................................6-4
Hoist Field Current (Strong Field) .............................................................................................................6-4
Hoist Field Current (Weak Field) ..............................................................................................................6-5
Swing Semi-Converter Pulse .....................................................................................................................6-6
Thyristor Firing Pulse (Swing Field) .........................................................................................................6-6
Swing Field Current Feedback ..................................................................................................................6-7
Swing Field Residual Voltage ...................................................................................................................6-7
Swing Voltage Waveform .........................................................................................................................6-8
Swing Voltage Waveform with One Thyristor Not Firing ........................................................................6-8
Crowd/Propel Semi-Converter Pulse .........................................................................................................6-8
Thyrister Firing Pulse (Crowd/Propel Field) .............................................................................................6-9
xxiii
Crowd/Propel Field Current Feedback ......................................................................................................6-9
Crowd/Propel Field Residual Voltage .....................................................................................................6-10
Crowd/Propel Voltage Waveform ...........................................................................................................6-10
Crowd/Propel Voltage Waveform With One Thyristor Not Firing .........................................................6-10
Hoist/Propel Armature Control Frame Circuit Card Location and Identification ...................................6-11
Hoist/Lower and Propel Forward/Reverse control Flow Chart With Booster System ............................6-12
Armature Thyristor Pulse .........................................................................................................................6-18
Hoist Converter Location .........................................................................................................................6-19
Pulse Amplifier Output Pulse ..................................................................................................................6-20
Pulse Amplifier Output Pulse (3 Pulses) .................................................................................................6-20
Pulse Generator Output Pulse ..................................................................................................................6-20
Armature Current Feedback (Lowering) .................................................................................................6-21
Armature Current Feedback (Hoisting) ...................................................................................................6-21
Current Adjusting Resistor ......................................................................................................................6-22
Voltage Feedback Adjusting Resistor ......................................................................................................6-22
Crowd/Propel Armature Control Frame ..................................................................................................6-23
Crowd/Propel Control Flow Chart ...........................................................................................................6-24
Crowd/Propel Converters ........................................................................................................................6-29
Pulse Amplifier Output Pulse (3 Pulses) .................................................................................................6-30
Armature Current Feedback (Crowd) ......................................................................................................6-31
Armature Current Feedback (Retract) .....................................................................................................6-31
Crowd Converter ......................................................................................................................................6-32
Swing Armature Control Frame ..............................................................................................................6-35
Swing Control Flow Chart .......................................................................................................................6-36
Swing Converter Cabinet .........................................................................................................................6-42
Pulse Amplifier Pulse (3 Pulses) .............................................................................................................6-43
Armature Current Feedback (Swing Right) .............................................................................................6-44
Armature Current Feedback (Swing Left) ...............................................................................................6-44
Swing Converter ......................................................................................................................................6-46
RPC Systems ..............................................................................................................................................7-2
RPC Switching Cabinet (Inboard Side) .....................................................................................................7-2
RPC Systems ..............................................................................................................................................7-3
RPC Switching Cabinet (Outboard Side) ..................................................................................................7-3
RPC Cabinet (Inboard Side) ......................................................................................................................7-5
RPC Indication ...........................................................................................................................................7-6
RPC Control Frame Components ..............................................................................................................7-6
xxiv
RPC Firing Pulse .......................................................................................................................................7-7
Typical Diverter Circuit .............................................................................................................................8-2
Diverter Module Testing Diagram .............................................................................................................8-3
Diverter Firing Circuit Assembly ..............................................................................................................8-5
Diverter Firing Circuit Pulse ......................................................................................................................8-6
Secondary Shutdown Circuit .....................................................................................................................8-7
Auxiliary Cabinet .......................................................................................................................................9-2
Auxiliary Cabinet Fault Indicators ............................................................................................................9-3
Transfer Cabinet ......................................................................................................................................9-22
Volt-Ohm-Milliammeter (89Z495) ..........................................................................................................10-1
DC Test Probe Connections .....................................................................................................................10-2
Test Probe Connections ...........................................................................................................................10-4
DC Resistance Test Probe Connections ...................................................................................................10-4
Digital Multimeter (89Z514D12) ............................................................................................................10-5
Tong Test Ammeter (89Z367) .................................................................................................................10-6
Meter Removal ........................................................................................................................................10-7
Lowering Range .......................................................................................................................................10-7
Thyristor Tester (89Z511D1) ...................................................................................................................10-8
Gate Test Circuit ......................................................................................................................................10-8
Forward Leakage Test Circuit .................................................................................................................10-9
Reverse Leakage Test Circuit ................................................................................................................10-10
Oscilloscope Operation ..........................................................................................................................10-12
Probe Components .................................................................................................................................10-13
Probe Schematic Diagram .....................................................................................................................10-14
Model 212 Oscilloscope Controls and Connections ..............................................................................10-14
Current Feedback Connections and Waveforms ....................................................................................10-15
Model 214 Oscilloscope ........................................................................................................................10-17
Model 97 Combination Oscilloscope and Digital Voltmeter ................................................................10-18
Brush Recorder Block Diagram .............................................................................................................10-19
Model 220 Brush Recorder (89Z471) ....................................................................................................10-20
Typical Brush Recording .......................................................................................................................10-21
Opening The Writing Table ...................................................................................................................10-21
Loading Paper Supply ............................................................................................................................10-21
Removing Paper Supply ........................................................................................................................10-22
Common Circuit Grounding Straps .......................................................................................................10-22
Threading Paper .....................................................................................................................................10-22
Monitoring Two Sources with a Common Connection .........................................................................10-23
Disconnection of Grounding Straps .......................................................................................................10-24
Monitoring Two Sources with Different References .............................................................................10-24
Astro-Med’s DASH II Model MT Recorder .........................................................................................10-25
Signal Input Connections .......................................................................................................................10-26
Front Panel Controls ..............................................................................................................................10-27
Loading Recorder with Z-Fold Thermal Paper ......................................................................................10-31
SLC-150 Programmable Controller .........................................................................................................11-1
External Wiring Schematics ....................................................................................................................11-4
Optional Remote Station (See Following Page for Descriptions) .........................................................11-14
xxv
PLC Lubrication Controller (See following Page for Descriptions) .....................................................11-15
Thyristor Assembly ..................................................................................................................................12-2
Typical dv/dt Network .............................................................................................................................12-3
xxvi
List of Tables
Index - Rack 3 Indicator Lights .................................................................................................................4-1
PLC-5 Processor Troubleshooting .............................................................................................................4-5
PLC-5 2-Slot Addressing Mode ................................................................................................................4-8
Hoist motion fault troubleshooting ............................................................................................................5-1
Crowd/Propel motion fault troubleshooting ..............................................................................................5-2
Swing motion fault troubleshooting ..........................................................................................................5-3
Settings for Circuit Board Switches and Potentiometer ............................................................................6-5
Hoist Control Monitor .............................................................................................................................6-13
Hoist/Propel Adapter ...............................................................................................................................6-13
Voltage Regulator ....................................................................................................................................6-13
Current Regulator ....................................................................................................................................6-14
Blocking Circuit .......................................................................................................................................6-14
Blocking Amplifier ..................................................................................................................................6-15
Firing Pulse Generator .............................................................................................................................6-15
Booster Circuit .........................................................................................................................................6-15
Firing Pulse Amplifier .............................................................................................................................6-16
Settings For Board Switches And Potentiometers (4100A) ....................................................................6-17
Oscilloscope Settings For Thyrister Firing Checks .................................................................................6-18
Crowd/Propel Adapter .............................................................................................................................6-25
Settings For Board Switches And Potentiometers (4100) .......................................................................6-28
Swing Adapter .........................................................................................................................................6-38
Settings For Board Switches And Potentiometers (4100) .......................................................................6-41
Front Hoist Blower Motor Fault ................................................................................................................9-4
Rear Hoist Blower Motor Fault .................................................................................................................9-5
Front Swing Blower Motor Fault ...............................................................................................................9-6
Rear Swing Blower Motor Fault ................................................................................................................9-7
Propel No. 1 Blower Motor Fault ..............................................................................................................9-8
Propel No. 2 Blower Motor Fault ..............................................................................................................9-9
Crowd Blower Motor Fault ......................................................................................................................9-10
xxvii
Converter No. 1 Blower Motor Fault .......................................................................................................9-11
Converter No. 1 Blower Motor Fault .......................................................................................................9-12
RPC Switch Blower Motor Fault .............................................................................................................9-13
Machinery House Blower Motor Fault ....................................................................................................9-14
Machinery Cab Blower Motor Fault ........................................................................................................9-15
Swing Lube Pump Front Motor Fault (2300XPA Only) .........................................................................9-16
Hoist Lube Pump Rear Motor Fault ........................................................................................................9-17
Dipper Trip Motor Fault ..........................................................................................................................9-18
Swing Lube Pump Rear Motor Fault (2300XPB Only) ..........................................................................9-19
Dipper Trip Motor Fault ..........................................................................................................................9-20
Measuring DC Volts ................................................................................................................................10-3
Measuring AC Volts ................................................................................................................................10-3
Measuring DC Resistance ........................................................................................................................10-4
Multimeter Connections and Switch Position .........................................................................................10-6
Thyristor Tests .........................................................................................................................................10-9
Thyristor Test Data ................................................................................................................................10-10
Comparison Oscilloscope - VOM ..........................................................................................................10-11
Display Controls ....................................................................................................................................10-15
Vertical Deflection Controls (Model 212) .............................................................................................10-16
Horizontal Deflection Controls (Model 212) .........................................................................................10-16
Trigger Controls (Model 212) ................................................................................................................10-16
Miscellaneous Controls (Model 212) ....................................................................................................10-17
Brush Recorder Controls .......................................................................................................................10-20
PLC Timer Addresses ..............................................................................................................................11-5
External Wiring Schedule ........................................................................................................................11-6
Thyristor Clamping Force ........................................................................................................................12-3
xxviii
DANGERS, WARNINGS, CAUTIONS and NOTICES are used throughout this manual to emphasize important and critical
instructions. Dangers, Warnings and Cautions always precede the paragraph or item to which they apply; Notices always follow the
paragraph or item to which they apply. For the purpose of this manual Dangers, Warnings, Cautions, and Notices are defined as
follows:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in
! DANGER death or serious injury. This signal word is to be limited to the most extreme situations.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
! WARNING
DANGER
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe practices.
! CAUTION
DANGER
NOTICE is used to indicate a statement of Company policy as the message relates directly or
indirectly to the safety of personnel or protection of property. This signal word is not associated
NOTICE directly with a hazard or hazardous situation and is not used in place of "DANGER",
"WARNING" or "CAUTION".
vii
P&H® MINING EQUIPMENT OFFICES
WORLDWIDE MINING HEADQUARTERS
4400 West National Avenue
Milwaukee, WI 53214-3684
P O Box 310
Phone: (414)671-4400 Fax: (414)671-7604
NORTH Hibbing, MN
P&H MinePro Services
Milwaukee, WI (Home Office) 3621 15th Avenue East
P&H MinePro Services PO Box 158-A
4400 West National Avenue Hibbing, MN 55746-0158
Milwaukee, WI 53214-3684 Phone: (218)262-3837
PO Box 310 Fax: (218)262-6323
Phone: (414)671-4400 Ogden, UT
Fax: (414)671-7604 P&H MinePro Services
2258 E. 6275 South
Casper, WY Ogden, UT 84403
P&H MinePro Services Phone: (801)475-1757
1935 North Loop Avenue Fax: (801)475-1758
Casper, WY 82601
PO Box 296 St. Albans, WV
Casper, WY 82602-0296 P&H MinePro Services
Phone: (307)237-1574 205 Smiley Drive
Fax: (307)235-7907 St. Albans, WV 25177-1587
Phone: (304)755-1007
Evansville, WY Fax: (304) 755-8595
1180 Iron Street Canada
P.O. Box 459
Evansville, WY 82636-0459 Harnischfeger Corporation of Canada, Ltd.
Phone: (307)237-5144 Vancouver
Fax: (307)237-5147 12391 No. 5 Road
Richmond, BC V7A 4E9, Canada
Gillette, WY Phone: (604)271-5115
P&H MinePro Services Fax: (604)271-6242
5834 Winland Drive
Gillette, WY 82718 Sparwood (Parts)
Phone: (307)685-4100 PO Box 1390
Fax: (307)685-4101 621 Douglas Fir Road
Sparwood, BC V0B 2G0, Canada
Gladewater, TX Phone: (250)425-0818
P&H MinePro Services Fax: (250)425-0665
4Mi North of Gladewater TX on Hwy 271
P.O. Box 472 Hinton (Parts)
Gladewater, TX 75647 113 King Street
Phone: (903)295-2770 Hinton, Alberta T7V 1G7, Canada
Fax: (903)295-2773 Phone: (403)865-3736
Fax: (403)865-8861
Harnischfeger Institute-Technical Communications P&H® Mining Equipment

VER 04, 01-98 iii TC_OFF04
P&H® Mining Equipment - MinePro Services Location
North York Chile

4 Lansing Square Ste 211 Otero SA P&H MinePro Services
North York, Ontario M2J 5A2, Canada Isidora Goyenechea 3250
Phone: (416) 499-5000 Piso 5
Fax: (416)499-5003 Las Condes, Santiago, Chile
Phone: 56-2/231 5833
Cornwall (Parts & Service) Fax: 56-2/231 6246
1411 Rosemount Avenue
Cornwall, Ontario K6J 3E5, Canada Antofagasta Shop
Phone: (613)930-4400 C/O Otero SA P&H MinePro Services
Fax: (613)930-4404 Av. Pedro Aguirre Cerda #651
Antofagasta, Chile
Phone 56-55/23-3449
Fax: 56-55/23-9188
SOUTH
Santiago (Parts & Service)
Mesa, AZ Apostol Santiago N18
Santiago, Chile
P&H MinePro (Mesa 2)
Phone: 56-2/776 2442 / 778 4908
1811 S. Alma School Road, Ste 215
Fax: 56-2/778 1198
Mesa, AZ 85210
Phone: (602)345-6007
Fax: (602)345-4040 Peru
P&H MinePro Services Peru S.A.
P&H MinePro Services (Mesa 1) Felipe Pardo y Aliaga 640 Piso 13
112 West Iron Avenue San Isidro, Lima, 00027 Peru
Mesa, AZ 85210-6105 Phone: 51-1/421-6160, 440-6541, 440-1196
Phone: (602)834-7656 Fax: 51-1/422-3593
Fax: (602)834-7807
Venezuela
Elko NV (Warehouse) Harnischfeger Venezuela, S.A. (Warehouse)
P&H MinePro Services Zona Industrial Matanzas Sur
5244 East Idaho Street UD-321, Transversal “C”, Entre
Elko, NV 89801 Calles 2y3, Galpon 14-02
Phone: (702)778-0740 Puerto Ordaz, Edo, Bolivar, Venezuela
Fax: (702)778-0744 Phone: 58-86/942825/942931
Fax: 58-86/943437
Mexico
Harnischfeger Mexico S.A. de C.V.
Paseo Valle Verde, No. 21 AUSTRALASIA
Col. Valle Verde
83200, Hermosillo, Sonora Mexico
Brisbane, Australia (Home Office)
Phone: 52-62/180864, 180870, 604790
Fax: 52-62/180911 71 Lytton Road
PO Box 7231
Brazi East Brisbane, Queensland 4169, Australia
Brazil Belo Horizonte (Service,Parts,Sales) Phone: 61-73/240-4600
Fax: 61-73/240-4666
Harnischfeger do Brazil
Avenida Portugal 4511/Bairro Itapoa
Hunter Valley
31710-400 Belo Horizonte, M.G., Brazil
Lot 11, Mount Thorley Road
Phone: 55-31/491-7636
Fax: 55-31/491-6181 PO Box 455
Mount Thorley, NSW 2330 Australia
Phone: 61-65/789-800
Fax: 61-65/789 888

VER 04, 01-98 iv TC_OFF04
P&H® Mining Equipment - MinePro Services Location
Mackay (Parts)
Lot 2, Glenella Road Great Britian
Glenella PO Box 816 P&H MinePro Services-Eurasia
Mackay, Queensland, Australia 4740 (Sales,Parts,Service)
Phone: 61-79/425-055 Harnischfeger (U.K.) Ltd.
Fax: 61-79/425-057 P.O. Box 12
Seaman way, Ince
Perth Wigan WN1 3DD
290 Collier Road United Kingdom
PO Box 265 Phone: 44-1942 610404
Bassendean 6054, W. Australia, Australia Fax: 44-192 610419
Phone: 61-9/270-0700
Fax: 61-9/270-0777 South Africa
P&H MinePro Services Africa
(Sales, Parts & Service)
442 Heidelberg Road, Tulisa Park
INTERNATIONAL Johannesburg, Republic of South Africa
PO Box 83676, South Hills 2136
Phone: 27-11/869-1335
Milwaukee, WI (Home Office) Fax: 27-11/869-0566
4400 West National Avenue Northern Cape
Milwaukee, WI 53214-3684 38 Ian Flemming Road
P.O. Box 310 PO Box 1617
Milwaukee, WI 53201-0310 Kathu 8446 South Africa
Phone: (414)671-7316 Phone: 27-5376/33074/5
Fax: (414)671-7236 Fax: 27-5376/33076
Beijing P&H MinePro Electrical Services

P&H MinePro Services-China 43-45 Lepus Road
Room 610, East Ocean Center Crown Mines Ext 8
24A Jianguo Menwai Dajie Johannesburg, Republic of South Africa
Beijing, China 100022 Phone: 27-11/839-2713
Phone: 86-10/6515-5803/04 Fax: 27-11/839-2798
Fax: 86-10/6515-5672

VER 04, 01-98 v TC_OFF04
Safe Operating
Practices for Mining Equipment Users
Preface 1. Appointed qualified operators, who have met the

requirements of the operation tests and physical and mental
A review of many safety sources including MSHA, OSHA, condition.
ANSI provisions and various individual mine safety policies 2. Qualified maintenance and test personnel, when required to
was conducted to develop these safe operating practices do so in the performance of their duties.
recommendations. The purpose of these recommendations is to
assist and support our customers in their safety efforts in 3. Inspectors qualified to operate the machinery.
preventing accidents.
OPERATION TESTS. Every employer should require that all
persons who will be authorized to operate a shovel or excavator
Introduction first pass an examination which accurately measures practical
knowledge of the equipment and proper methods to be used in
P&H shovels and excavators are carefully designed, operating the shovel or excavator.
manufactured, and tested. When used properly by qualified
operators, they will give safe, reliable service. There are P&H PHYSICAL AND MENTAL CONDITION. An operator must
offices world-wide to answer any questions about P&H meet the following physical and mental qualifications:
products or their safe use. The World Sales andService
headquarters for P&H Mining Equipment is: 1. An operator must possess good hearing ability as well as
good vision (corrected or uncorrected). Good depth perception
Harnischfeger Corporation is also required, especially where truck loading is critical or
4400 West National Avenue must be accomplished at some distance from the operator.
P.O. Box 310 2. An operator must not be afflicted with any known health
Milwaukee, WI 53201 USA condition or disability which could cause a sudden inability to
Telephone: (414) 671-4400. react quickly.
Because shovels and excavators are complex and massive 3. An operator who is taking medication prescribed by a doctor
equipment and have the ability to lift and move heavy loads, must present written assurance from his doctor that the
they also have a potential for accidents if safe operating medication will not affect the operator's ability to operate the
practices are not followed. This booklet is intended to help shovel or excavator in a safe manner.
prevent accidents which could result in injury, death, or
4. An operator who is known, or suspected, to be under the
property damage.
influence of alcohol or drugs must not be allowed to operate
equipment under any circumstances.
General safe practices for working on machinery must be
followed as well as the safe operating practices. The following 5. The operator must have a good attitude towards safety at all
recommendations are provided to supplement customer/owner, times.
local, or national safety codes, rules or procedures.
Mine Management's Responsibility

Operator Qualifications
Management must ensure that operators are trained, competent,
GENERAL. Only the following personnel should be permitted physically fit and, if required, licensed. Good vision is required,
to operate a shovel or excavator: as are good judgement, coordination and mental ability. Any
ix
person who lacks any of these qualities must not be allowed to over people. He must never use the shovel or bucket to lift or
operate a shovel or excavator. transport people.
Management must maintain its equipment in a safe operating A warning signal must be given by the operator prior to starting,
condition and must require the equipment's operation to operating, or traveling the shovel or excavator.
immediately stop if an unsafe condition is found.
Management must ensure that the ground crew have good Responsibilities Of All Crew Members
vision and sound judgement, know standard signals and be able
to give travel signals clearly. They must have enough Any unsafe condition or practice must be corrected or reported
experience to be able to recognize hazards and signal the to the job supervisor and equipment operator.
operator to avoid them.
Everyone who works around shovels or excavators, including
Management must assign a job supervisor at the site to be support people and maintenance personnel, must obey all
responsible for overall job safety. Shovel or excavator operators warning signs and watch out for their own safety and the safety
and crew members must know who has been assigned this of others. Crew members setting up machines or handling
responsibility. maintenance or repairs are expected to know proper procedures
including lockout/tagout practices.
Crew members must be given specific safety responsibilities
and instructed to report any unsafe conditions to their Watch for hazards during operations and alert the operator of
supervisors. dangers such as the unexpected presence of people, other
equipment, unstable ground and bank conditions or
Management must assign specific people to coordinate and approaching storms.
direct the service, repair, inspection and maintenance process
for the shovel or excavator during each shift with specific
methods to de-energize equipment before starting the work and Planning the Job
to lockout and tagout equipment until ready for operation.
Most accidents can be avoided by careful job planning. The
Management must assign qualified people with proper tools and person in charge must have a clear understanding of the work to
protective equipment for specific work assignments. be done, consider dangers or hazards, develop a plan to do the
job safely, and then explain the plan to all concerned. Factors
Management must maintain a safety program which includes such as the following should be considered:
both instructions and training for employees on shovel or
excavator safety. • How can the shovel tail cable be safely moved at the work site?
Management must ensure that during night operation, suitable • Is there other equipment, power lines or structures which must
lighting is provided. be moved or avoided during movement of the shovel?
Operator's Responsibility • Is the surface strong enough to support the machine and load?
Safety must always be the operator's most important concern. • How and where will the removed materials be unloaded?
He must refuse to operate when he knows it is unsafe and
consult his supervisor when safety is in doubt. • What steps will be taken to keep unnecessary people and
equipment at a safe distance from the work area?
He must read and understand the Operator's Manual, all
instructions and signs on the equipment. He must see that the These factors are not meant to be exhaustive, but only a starting
machine is in proper order before operating. point. Each job must be individually considered.
He must be alert, physically fit, and free from the influences of

alcohol, drugs, or medications that might affect his sight, Operator's Functional Checks
hearing, or reactions.
The operator must make a safety check before starting to work
He must ensure that people, equipment, and material are kept each shift to see that the machine is in proper order. Some
out of the work area. He must never operate the dipper or bucket things to check are:
x
• Check for warning tags or lockout tags on the starting controls; 4. Always start and stop swing movements smoothly and swing
do not operate the controls until the tag has been removed by at speeds that will keep the dipper load from spilling. Rapid
the person who placed it there, or by a qualified person. swings, sudden starts or sudden stops can cause the load to spill
and damage swing machinery.
• Check with mine maintenance and operations management to
see that periodic maintenance and inspections have been 5. Keep windows clean. Do not operate if you cannot see
performed and all necessary repairs made. clearly enough to operate. Dirty windows, darkness, bright
sunlight, fog, rain, and other conditions can make it difficult for
• Consult with mine management that scheduled inspection of the operator to see.
load carrying members such as wire rope (dipper trip lines,
hoist rope, suspension lines), boom, dipper handle and dipper 6. Carelessness in getting on and off equipment can result in
has been conducted. serious injuries. Always wait until the operator has been
notified and the shovel or excavator has stopped all movement
• Check that all equipment guards are in place and all inspection before attempting to climb onto the shovel or excavator. Do not
and cover plates are closed and locked. jump on or off. Use both hands and make sure you have good
footing.
• On hydraulic shovels, check for evidence of hydraulic oil
7. Keep the machine clean and dry. Slippery floors and steps,
leaks.
tools, trash, or other loose items can cause slips and falls.
• Look inside, outside and underneath the shovel or excavator to 8. Exceeding the slope or grade limitations given for your
make sure everything is clear before starting or energizing specific shovel can cause a tip over or run away condition
the machine. resulting severe injuries, death or property damage. Prior to
propelling, always determine the slope or grade limitations for
• After starting the shovel or excavator, check all gauges and
your specific machine and never travel, park or operate on site
indicators for proper readings and operation.
slope conditions which exceed these limitations.
• Test all controls for proper operation and control ability before 9. As with all heavy equipment, care must be taken when
machine operation or travel including a check of brakes. shovels or excavators are moved around the job site. Watch for
people, other equipment, low or narrow clearances, ground
• Check audible warning devices and alarms used for backup bearing limits, and steep hills or uneven terrain. Use a
warning for proper operation. signalman when traveling. Know the height, width, and weight
of the machine. Always secure equipment before traveling. Do
• During operation, be alert for unusual noises or vibrations;
not travel with people riding on the outside of the machine or
look and smell for unusual smoke or fumes.
inside the machinery house.
Operating Instructions 10. Leaving a shovel or excavator unattended can be very

dangerous unless proper precautions are taken. At night, or
1. Determine the load bearing capacity of the ground or other conditions of poor visibility, lights, flares, or other warning
surface on which machines will be operating. Be sure the devices must be posted to identify the parked shovel's location
machine is adequately supported. Avoid soft or unstable for other traffic. Before leaving his seat, the operator must take
ground, areas with high water tables, and partially frozen the following steps to prevent the shovel or excavator from
ground. When machines are working near benches, the benches moving:
should be shored or sloped by appropriate equipment to prevent
cave-ins or slides. • Lower the dipper to the ground.
2. Shovels or excavators should never be used to lift people.
• Return all controls to the neutral position.
Use ladders, scaffolds, elevated work platforms or other
equipment designed to lift people.
• Set all brakes.
3. Prior to servicing or repairing the shovel or excavator, follow
lockout and tagout procedures. Both OSHA and MSHA Before leaving the shovel or excavator, in addition to the
regulations require lockout/tagout procedures. Injury, death, previous steps required by the operator, the following should be
and damage can occur if the shovel or excavator is started before done:
servicing is finished. Never start or operate the equipment if
lockouts or tagouts are on the controls. Look inside, outside, • Shut off the master control power switch on electrically-
under and around the equipment to be sure everyone is clear. powered shovels or excavators.
xi
• Verify that all electrical cabinets are closed and locked and that • De-energize control functions.
all electrical components guards are installed.
• Comply with lockout and tagout procedures.
• Disengage the engine clutch and shut off the engine on engine-
3. Injury, death, and damage can occur if the machine is started
powered shovels or excavators.
before servicing is finished. Never start or operate the
11. Wire rope running over drums and through sheaves create equipment if lockouts or tagouts are on the controls. Prior to
pinch points. Do not use your hands to guide wire rope onto starting the machine, look under, within, and around the
drums. Use rope guides or prescribed procedures. Keep equipment to be sure everyone is clear.
clothing and all parts of the body away from running rope and
4. Specific inspection, service and maintenance instructions for
the machinery that moves the rope.
P&H shovels or excavators are available from product manuals
12. Rocks too large to be handled safely must be broken before and the P&H service network. Always read and follow
loading to avoid the hazard of falling and ricocheting rocks. instruction manuals and use the P&H service network for
assistance.
13. Shovels or excavators with electric tail cables can break the
cable connection or crush the cable when traveling. Maintain 5. On hydraulic shovels, release system pressure before
cable slack while operating and traveling. Use signalmen attempting to make adjustments or repairs. Pressure in
during traveling to prevent damaging to the cable or cable hydraulic systems can be retained for long periods of time. If
connection. not properly released before maintenance people attempt to
work on the hydraulic system, this pressure can allow
14. Make sure that the shovel or excavator house or bucket does machinery to move or cause hot oil and hose ends to shoot out
not hit obstructions when swinging. Establish clearances for the at high speed.
machine after each relocation with job site procedures.
6. Maintenance and service can involve the handling of heavy
15. Cave-in can occur when excavating in a pit or along a high parts or components which can injure personnel. Use lifting
wall. Do not undercut the bank but remove the uppermost and handling equipment along with blocking to remove,
material first or take other appropriate precautions. support, and install heavy parts.
16. People can be pinched, entangled or crushed by moving 7. Make sure both ends of booms or cylinders are supported and
machinery. Personnel should not place any part of their body or the boom suspension lines completely slacked off before
clothing on or near any rotating machinery, gears, pinions, removing pins. Never stand on, inside, or under booms during
ropes, cables or crawlers while the machine is in operation. erection or disassembly. Pin-connected booms may fall if not
properly supported when removing or installing pins.
Maintenance Work Precautions 8. In regard to inspection and retirement of wire rope used on
surface mining machines:
Inspection, service and maintenance are essential elements in
the proper operation and performance of shovels and • Mine management shall provide and appoint qualified
excavators. The following recommendations are provided to personnel to inspect, prepare and retain written reports on
supplement past experience, knowledge and common sense of a wire rope inspections.
serviceman concerning potential hazards associated with
inspection, service and maintenance. • An inspection procedure should be established by Mine
Management for each wire rope application on their mining
1. Prior to undertaking any work on the equipment, the shovels or excavators.
personnel performing the work shall notify the operator about
the nature and location of the job. Appropriate lockout and • Unless instructed otherwise, the frequency of inspections shall
tagout procedures must be determined and followed by all be established based upon operating shifts, days, weeks or
individuals involved to guard against potential hazards. months depending upon anticipated rope life and working
conditions.
2. Before maintenance or service is attempted, the operator
must park the machine in a location to avoid hazards such as • An average wire rope life shall be established based upon the
falling rocks and unstable ground. After parking the machine, number of operating cycles, volume of material handled or
the operator shall: weight of material handled. Replacement is determined from
this established rope life analysis.
• Set the dipper on the ground.
9. MSHA procedures require all wire rope be inspected daily to
• Set all brakes. determine whether it should be replaced.
xii
As a minimum, wire rope replacement should be performed kill or seriously injure people servicing, repairing or working on
when any of the following conditions exist: the machines. Inspection, maintenance or service of any
electrical component must be done by qualified personnel. All
• Severe abrasion, scrubbing, peening, or kinking, or broken people working on or around the equipment should read and
outer wires. obey hazard signs and always use lockout and tagout
procedures.
• Crushing, or other damage that distorts the rope's structure.
• Severe reduction of rope diameter or an observable increase in

rope lay. 12. All guards, signs, warning devices and guarding devices
must be in place and in working conditions before the shovel or
• Bird-caging or other distortion indicating uneven distribution excavator is placed back in operation after inspection, service
of load between rope strands. and maintenance.
• Evidence of severe corrosion, particularly in the vicinity of

attachments.
13. Loose or missing hardware, bolts, or nuts should be properly
• Uneven stretch of multiple ropes. tightened or replaced with the manufacturer's specified
hardware. Refer to P&H Service and Parts sources for
• Heat damage from any source. replacement parts.
• A rapid increase in the number of broken wires.

10. Wire rope end connections must be installed properly and 14. If there is not enough wire rope on the drum, the rope can be
inspected daily. pulled off. Allow for at least two full wraps of wire rope on
drums when replacing the rope.
• Wire rope secured with a wedge socket should be installed so
that the load line is in a straight line pull with the eye of the
socket; and the loaded part of the rope is not kinked where it
15. Electrical junction boxes for electrical motors can contain
leaves the wedge. The rope end should always protrude at
high voltage electrical power from multiple sources. Before
least 6 to 9 inches beyond the socket. Attach a short piece of
performing service on electrical components within electrical
wire rope to the rope end with two wire rope clips to prevent
junction boxes, determine that all electrical power from all
the rope end from slipping out of the wedge socket.
sources has been disconnected and locked out. Test the
11. Electrically powered shovels or excavators operate using components within the electrical junction box to verify the
high voltage wiring, components and systems. This voltage can electrical power is disconnected.
xiii
SECTION 1
GENERAL INFORMATION
INTRODUCTION di/dt - The rate of change of current with respect to time.
The purpose of this troubleshooting guide is to provide dv/dt - The rate of change of voltage with respect to time.
guidance to the mine electrical staff when it becomes necessary
to troubleshoot the Electrotorque control system. Whenever ENERGY - The capacity to do work.
feasible, the procedures outline, input then output checks, to
isolate a defective component. module and indicator panels, a FEEDBACK - A portion of a system output that is returned to
number of test instruments are necessary to aid in the system input.
troubleshooting. The descriptions and proper uses of these
instruments are outlined in Section X. FIELD SEMI-CONVERTER BOARD - A circuit board that
generates and controls the trigger pulses for the SCRs in the
A complete set of schematics is required in order to perform the swing field and crowd/propel field semi-converters.
procedures described in this manual. The schematics must be
matched with the serial number on the machine being tested. FILTER - A circuit that offers little opposition to some
frequencies while blocking other frequencies.
ELECTRICAL SYMBOLS
INDICATOR PANEL - A section of the control cabinet that
contains fault lights. These lights indicate which fault has shut
Electrical symbols frequently used in this manual and in the excavator down.
Electrotorque Service Bulletins are illustrated in Figures 1-1
through 1-14.
INVERSION- (OR REGENERATION) - The conversion of the
mining shovel’s mechanical and potential energy to electrical
TERMINOLOGY energy. The rate at which this is done is the power return to the
network.
Certain terms are frequently used in this manual. For better
METER MODULE - A section of the control cabinet where the
understanding, several are defined below.
test selector and three meters are located. The test selector
switch puts the shovel in either the RUN, ARMATURE TEST,
BRIDGE - A configuration of diodes or SCRs for converting FIELD TEST, CONTROL TEST, or AUXILIARIES TEST
AC voltage to DC voltage. Mode. The meters monitor armature currents, armature
voltages, field currents, and control voltages.
CONTROL FRAME - A group of circuit boards for controlling
the output of a converter. MOTION CHARACTERISTIC - The speed versus torque
relationship that is designed for optimum motion efficiency and
CONTROL PULSES - Signals that are generated by the control mechanical and electrical life.
frame and go to pulse transformers.
OPERATOR’S CONSOLE - A stand in the operator’s cab that
CONVERTER - A device that converts information from one contains the START and STOP pushbuttons, the brake
form to another. In this case, a system of one or more bridges for RELEASE and SET pushbutton, the CROWD and PROPEL
converting AC to DC. pushbuttons, etc.
1-1
PHASING- (OR TIMING) -The DC voltage from the converter SEMICONVERTER - A bridge that contains three SCRs and
depends on the phase relationship between the control pulses three diodes. It can convert 3&zsl. AC voltage to a regulated DC
and the AC converter voltage. Phasing is the shifting of this voltage but it cannot invert DC voltage to AC.
phase relationship for a differential converter output.
THYRISTOR OR SCR - (SILICON CONTROLLED
POWER - The rate at which energy is converted from one form RECTIFIER)-The most common type of thyristor. A
to another. semiconductor device that blocks voltage of either polarity until
an appropriate signal is applied to the gate when it conducts in
POWER FACTOR - The ratio of power to apparent power. the forward direction. Once the SCR conducts, the gate has no
Apparent power is the kilovoltamperes drawn by a system. influence on its operation. Conduction stops when the current
drops below a certain level.
REACTIVE POWER - The voltamperes required to energize an
inductive or capacitive load.
TORQUE - A force that tends to produce rotation.
REGULATE - To control.
TRANSDUCTOR - A device that is used to measure DC
REVERSING BRIDGE - A connection of two bridges where current. It is not current direction sensitive.
the anodes of one bridge are common with the cathodes of the
other for producing both DC current directions. TRIGGER PULSE (OR FIRING PULSE) - The pulse that goes
to the gate and cathode of an SCR to start conduction.
RESONANCE - When input signals at a certain frequency
cause extremely large oscillations. VARISTOR - This is a voltage transient suppressor.
1-2
Figure 1-1. Common Electrical Symbols
1-3
Figure 1-2. Common Electrical Symbols (Continued)
1-4
Figure 1-4. Simple Logic Symbols (Continued)
Figure 1-3. Simple Logic Symbols Figure 1-5. Bistable Element (Memory Element)
1-5
Figure 1-7. Monostable Elements
Figure 1-8. Astable Elements
Figure 1-6. Bistable Element (Continued) Figure 1-9. Delay Elements
1-6
Figure 1-10. Level Discriminator
Figure 1-11. Amplifier Circuits Figure 1-12. Amplifier Circuits (Continued)
1-7
Figure 1-13. Amplifier Circuits (Continued)
Figure 1-14. Other Symbols
1-8
SWING MOTOR
AND TRANSMISSION
LUBE TANKS
IN ROOM
AUXILIARIES
CABINET
CONTROL
CABINET
TRANSFER PLC
CABINET CABINET
HOIST
MOTOR
HOIST 120VAC
LOAD CENTER
GEARCASE
AIR COMPRESSOR
AND RECEIVER LOW VOLTAGE
COLLECTOR
HOIST DRUM
HOIST CONVERTER
MOTOR CABINET
AUX./FIELD/LIGHT
TRANSFORMER
SWING MOTOR
460 VAC AND TRANSMISSION
LOAD CENTER
HIGH VOLTAGE
CABINET
REACTIVE POWER
COMPENSATION CABINETS
MAIN
TRANSFORMER
DIPPER TRIP
FIELD BREAKERS RESISTORS
Figure 1-15. Model 2300XPB Equipment Locations
1-9
SWING MOTOR
AND TRANSMISSION
LUBE TANKS
IN LOWER ROOM
CONTROL
CABINET
AIR COMPRESSOR
IN UPPER ROOM
PLC
CABINET
HOIST
MOTOR
120VAC
HOIST LOAD CENTER
GEARCASE
AIR
RECEIVER LOW VOLTAGE
COLLECTOR
HOIST DRUM
HOIST
MOTOR
HIGH VOLTAGE
CABINET
MAIN
TRANSFORMER
SUPPRESSION
CABINET
SWING MOTOR
AND TRANSMISSION
AUXILIARIES
TRANSFORMER
REACTIVE POWER
COMPENSATION CABINETS
TRANSFER CONVERTER FIELD BREAKER 480 VAC AUXILIARIES

CABINET CABINET LOAD CENTER
Figure 1-16. Model 2800XPB and 4100 Equipment Locations
1-10
AUXILIARIES
SWING MOTOR
85 AND 138 AND TRANSMIS
GALLON LUBE
TANKS IN LOWER
ROOM
CONTROL
HOIST CABINET
MOTOR
PLC
CABINET
AIR
COMPRESSOR
120VAC
HOIST LOAD CENTER
GEARCASE
LIGHTING
AIR CONTACTORS
RECEIVER
LOW VOLTAGE
COLLECTOR
HOIST DRUM
HOIST LIMIT
SWITCH
SENSOR
HOIST
MOTOR
HIGH VOLTAGE
CABINET
HOIST DISC
BRAKE MAIN
TRANSFORMER
SUPPRESSION
CABINET
SWING MOTOR
AND TRANSMIS
AUXILIARIES
TRANSFORMER
REACTIVE POWER
COMPENSATION
CABINETS GROUND
FAULT
CABINET
TRANSFER CONVERTER DIPPER TRIP 480 VAC

CABINET CABINET RESISTORS FIELD BREAKER LOAD CENTER
Figure 1-17. Model 4100A Equipment Locations
1-11
SECTION 2
CONTROLS
GENERAL 5. SWING BRAKE SET BUTTON. Depressing the brake set

button causes the swing brakes to return to their spring set
This section covers the controls in the operator’s cab. Operators position simultaneously.
should be familiar with these controls to ensure the proper
operation of the mining shovel.
6. SWING BRAKE RELEASE BUTTON. Depressing the
brake release button causes the swing brakes to be released.
CONTROLS-FLUSH MOUNTED
PANELS 7. SWING BRAKE RELEASE INDICATOR. This green
indicator lamp illuminates when the swing brakes are released.
A description of the standard controls on early Model 4100
mining shovels is listed below. The numbers of each control as
listed correspond to the numbers in Figure 2-1. The location of 8. HOIST BRAKE SET. Depressing the brake set button causes
some controls may vary, depending on the installation of special the hoist brakes to return to their spring set position
optional items. simultaneously.
1. MASTER CONTROL CONSOLES. The master control
consoles are located on both sides of the operators seat. 9. HOIST BRAKE RELEASE. Depressing the brake release
button causes the hoist brakes to be released simultaneously
2. STOP BUTTON. Depressing the stop button causes the
when the excavator is in the HOIST/CROWD mode.
excavator to shut down resulting in the setting of all brakes. If a
fault has shut the excavator down, start-up is accomplished by
first pressing the STOP button and then pressing the START
10. HOIST BRAKE RELEASED INDICATOR. This green
button.
indicator lamp illuminates when the hoist brakes are released.
3. START BUTTON. Depressing the start button causes
multiple electrical functions to sequence. After all the functions
have properly sequenced the excavator can be operated. 11. CROWD BRAKE SET BUTTON. Depressing the brake set
button causes the crowd brake to return to its spring set position.
NOTICE
12. CROWD BRAKE RELEASE BUTTON. Depressing the
There is a required function referred to as DEBLOCK- brake release button causes the crowd brake to be released.
ING which should be practiced by the operator each
and every time the excavator is started. Prior to press-
ing the START button the operator should always press 13. CROWD BRAKE RELEASED INDICATOR. This green
the STOP button. This action sets up the electronic indicator lamp illuminates when the crowd brake is released.
systems, if required, for a proper machine start se-
quence.
14. HOIST/CROWD BUTTON. Depressing the HOIST/
4. SYSTEM RUN INDICATOR. This green indicator lamp is CROWD transfer button causes electrical circuits to sequence
illuminated when all functions have properly sequenced and the and sets up the controls to permit the excavator to function in the
machine is ready for operation. HOIST/CROWD (digging) mode.
2-1
ted to run at idle with the brakes set. The machine must
NOTICE be shut down if the thermal overload does not reset af-
ter approximately fifteen minutes.
The excavator will always be in the hoist/crowd mode
when started. This is true even if the excavator was in 22. GROUND FAULT INDICATOR. This amber lamp
the propel mode at shutdown. illuminates if a ground fault is present in any of the secondaries
15. HOIST/CROWD INDICATOR. This green indicator lamp of the main field or auxiliary transformers. This is a fault
illuminates whenever the excavator is in the HOIST/CROWD indicator only and the proper electrical maintenance personnel
mode of operation. should be notified. The lamp will remain on until the indicator
is reset. The main fault panel will indicate the system with the
16. PROPEL MODE TRANSFER BUTTON. Depressing the fault.
propel transfer button causes electrical circuits to sequence, sets
up the controls, and releases the propel brakes to permit the 23. HEATER/BLOWER SWITCH. This switch actuates the
excavator to function in the PROPEL (travel) mode. heater and blower for the heating units located in the operator’s
coop.
! CAUTION
DANGER 24. TIME METER. The meter records the total time that the
excavator has been operated.
The transfer from Hoist/Crowd to Propel or from
Propel to Hoist/Crowd must always be done with
25. AC VOLTMETER. This meter indicates the voltage
the excavator at complete rest because the hoist and
available at the auxiliary motors and control circuits.
crowd brakes or the propel brakes set when the
transfer occurs.
26. MOTOR HEATER CONTROL SWITCH. This two way
17. PROPEL MODE INDICATOR. This green indicator lamp switch activates the heater strips within the electric motors.
illuminates when the excavator is in the PROPEL mode of These heaters and control are options for specific weather
operation. conditions.
18. FAULT PANEL INDICATOR RESET BUTTON. This
27. COOP LIGHT SWITCH. This switch controls the lights in
button may be used to reset the fault indicators located on the
the operator’s coop.
control cabinet in the machinery house. Another reset button
having the same function is located at the control cabinet.
28. CONSOLE LIGHT SWITCH. This switch controls the
19. GROUND FAULT INDICATOR RESET. Depressing this console illumination.
button will reset the indicator latching circuits. The reset button
is duplicated on the control cabinet. 29. FLOODLIGHT SWITCH. This switch, when placed in the
ON position, actuates all of the exterior floodlights.
20. FAULT PANEL INDICATOR. This red lamp illuminates if
a fault is registered on the fault rack of the PLC control cabinet. 30. WINDSHIELD WASHER CONTROL. Press and hold this
button to spray windshield washer solvent on the windshield.
NOTICE
31. WINDSHIELD WIPER CONTROLS. Rotate these controls
Any fault indicator on the operator’s console requires to actuate and regulate the upper and lower windshield wipers.
an immediate visual inspection of the fault rack and
notification of the proper maintenance personnel. 32. LEFT HAND CONTROLLER. This controller (joystick)
provides the means of controlling the crowd and retract motions
21. DC MOTOR OVERLOAD INDICATOR. This red lamp while in the HOIST/CROWD mode and the left crawler propel
illuminates when the DC motor registers an overheating motions while in the PROPEL mode. This controller also
condition. A pulsating alarm will sound when this lamp is controls the dipper trip function, and air horn. In the crowd and
illuminated. propel modes, this joystick controller allows two operations to
be performed simultaneously. For example, the dipper handles
NOTICE may be operated at the same time the dipper trip mechanism is
operated or the air horn sounded. The speed of the dipper
The thermal overloads will reset themselves as the mo- handles (crowd) or the left propel motion, is directly dependent
tor or motors cool. The affected motor will cool much on the amount the controller handle is moved from its normal
faster if production ceases but the excavator is permit- vertical (neutral) position.
2-2
21 22 19 37
01 03 02 24 25
20
38
18
39 04
08
40 11
09
33 12
10 32
29 13
05
14
27
06 16
28
07 15
26
17
34 35 36 30 31 23
01. CONTROL CONSOLES 21. DC MOTOR OVERLOAD INDICATOR

02. STOP BUTTON 22. GROUND FAULT INDICATOR
03. START BUTTON 23. HEATER/BLOWER CONTROL SWITCH
04. RUN INDICATOR LIGHT 24. TIME METER INDICATOR
05. SWING BRAKE SET BUTTON 25. AC VOLTMETER
06. SWING BRAKE RELEASE BUTTON 26. MOTOR HEATER CONTROL SWITCH
07. SWING BRAKE RELEASED INDICATOR 27. COOP LIGHT SWITCH
08. HOIST BRAKE SET BUTTON 28. CONSOLE LIGHT SWITCH
09. HOIST BRAKE RELEASE BUTTON 29. FLOOD LIGHT SWITCH
10. HOIST BRAKE RELEASED INDICATOR 30. WINDSHIELD WASHER CONTROL
11. CROWD BRAKE SET BUTTON 31. WINDSHIELD WIPER CONTROL
12. CROWD BRAKE RELEASE BUTTON 32. CROWD/PROPEL/DIPPER TRIP CONTROLLER
13. CROWD BRAKE RELEASED INDICATOR 33. HOIST/PROPEL/SWING CONTROLLER
14. HOIST/CROWD MODE TRANSFER BUTTON 34. LUBE CYCLE START PUSHBUTTON - UPPER
15. HOIST/CROWD MODE INDICATOR 35. LUBE CYCLE START PUSHBUTTON - LOWER
16. PROPEL MODE TRANSFER BUTTON 36. LUBE CYCLE START PUSHBUTTON - OPEN GEAR
17. PROPEL MODE INDICATOR 37. EMERGENCY STOP PUSHBUTTON
18. FAULT PANEL INDICATOR RESET BUTTON 38. ANNUNCIATOR - MOTOR OVERLOAD
19. GROUND FAULT INDICATOR RESET BUTTON 39. ANNUNCIATOR - DELAYED SHUTDOWN
20. FAULT PANEL INDICATOR 40. ANNUNCIATOR - LUBE ALARM
Figure 2-1. Operator Control Locations - Model 4100
2-3
33. RIGHT HAND CONTROLLER. This controller (joystick) 40. ANNUNCIATOR - LUBE ALARM. This audible alarm
provides the means of controlling the hoisting and lowering will sound with a slow pulsating tone whenever there is a lube
motions while the machine is in the HOIST/CROWD mode and system fault. The volume of this alarm can be adjusted by
the right crawler propel motions while in the PROPEL mode. rotating the face plate.
This controller also controls the swinging motions in either
mode of operation. The joystick controller allows two
operations to be performed simultaneously. For example, the
dipper may be raised or lowered while swinging the upper. The
CONTROL IDENTIFICATION - RAISED
speed that the dipper is raised or lowered (hoist) or that the right CONSOLES
crawler propels is directly dependent on the amount the
controller handle is moved from its normal vertical (neutral)
position. Swing acceleration and deceleration is also controlled A description of the standard controls on Models 2300XPB,
by controller handle movement. 2800XPB, 4100A and later Model 4100 mining shovels is listed
below. The numbers of each control as listed correspond to the
numbers in Figure 2-2. The location of some controls may vary,
depending on the installation of special optional items.
34. LUBE CYCLE START PUSHBUTTON - UPPER. This
pushbutton actuates the automatic lubrication controller to
lubricate the upper. 1. HOUR (TIME) METER. The time meter records the total
time the shovel has been operated. This meter measures time in
units of full hours.
35. LUBE CYCLE START PUSHBUTTON - LOWER. This
pushbutton actuates the automatic lubrication controller to 2. STOP PUSHBUTTON. Depressing this RED stop
lubricate the lower. pushbutton will shut down the shovel, setting all brakes. If a
fault has shut down the shovel, start the shovel by first pressing
the STOP button and then depressing the START pushbutton.
36. LUBE CYCLE START PUSHBUTTON - OPEN GEAR.
This pushbutton actuates the automatic lubrication controller to 3. START PUSHBUTTON/ON INDICATOR. Depressing this
supply open gear lubricant to the various crowd and swing start pushbutton/on indicator causes multiple electrical
components. functions to sequence on. After all of the functions have
properly sequenced, the GREEN on indicator will illuminate
signaling the shovel is ready for operation.
37. EMERGENCY STOP PUSHBUTTON. Depressing the
emergency stop pushbutton shuts down the operation of the
shovel, sets all brakes and removes power from the PLC outputs
(110/120 VAC). This pushbutton must be manually pulled out NOTICE
to resume normal start up procedures. Each time the shovel is started, deblocking must be
practiced by the operator. To deblock, press the RED
stop pushbutton. This action sets up the necessary
38. ANNUNCIATOR - MOTOR OVERLOAD. This audible electronic conditions for proper shovel start-up.
alarm will sound with a continuous tone when any of the DC
motors are in an over temperature or overload condition. The
4. CROWD INDICATOR/PUSHBUTTON (HOIST/CROWD).
volume of this alarm can be adjusted by rotating the face plate.
Depressing this indicator/pushbutton causes electrical circuits
to sequence and set up the controls to permit the shovel to
function in the hoist/crowd (digging) mode. When proper
39. ANNUNCIATOR - DELAYED SHUTDOWN. This audible control sequence set-up has taken place, the GREEN crowd
alarm will sound with a fast pulsating tone when the shovel has indicator lamp will illuminate, and will remain illuminated as
entered a delayed shutdown. The volume of this alarm can be long as the shovel remains in the hoist/crowd mode of
adjusted by rotating the face plate. operation.
2-4
Depress this pushbutton to release the crowd brakes and permit
NOTICE operation of the crowd function through the use of the LEFT
CONTROLLER. Be prepared to control the movement of the
The shovel will always be in the hoist/crowd mode dipper handles with the use of the crowd control when the
when started. This is true even if the shovel has been crowd brakes release. Activation of this pushbutton will cause
shut down while in the PROPEL mode. the green CROWD BRAKES RELEASED INDICATOR to
illuminate.
5. PROPEL INDICATOR/PUSHBUTTON.
9. SWING BRAKES RELEASE INDICATOR/

! WARNING
DANGER PUSHBUTTON. This GREEN indicator will illuminate when
the swing brakes are in the released state.
Activating PROPEL MODE will release the propel
brakes, which may result in unexpected machine
movement. Unexpected hoist, crowd, or propel
movement can cause injury, death, or equipment ! WARNING
damage. Set all brakes using the ALL BRAKES
DANGER
SET PUSHBUTTON prior to depressing the PRO- Releasing the swing brakes will allow the upper to
PEL PUSHBUTTON. rotate, which can cause injury, death, or property
damage. Use the swing controls to prevent move-
Depressing this pushbutton will cause electrical circuits to ment of the upper. Watch for unexpected personnel
sequence, set up controls, and release the propel brakes and equipment near the shovel.
allowing the shovel to function in the propel (travel) mode.
Propel brakes can be set by depressing the CROWD
PUSHBUTTON and transferring control operation back to Depress this pushbutton to release the swing brakes and permit
hoist/crowd mode. When proper control sequencing has taken operation of the swing function through the use of the RIGHT
place, the GREEN propel indicator lamp will illuminate and CONTROLLER. Be prepared to control the turn of the upper
remain illuminated as long as the shovel remains in the propel with the swing controls as the swing brakes are released.
mode of operation. Activation of this pushbutton will cause the green SWING
BRAKES RELEASED INDICATOR to illuminate.
6. CROWD BRAKE SET PUSHBUTTON. Depress this
pushbutton to set the crowd brakes and prevent operation of the
crowd function. Activation of this control will cause the green 10. OPEN GEAR LUBE PUSHBUTTON/INDICATOR. This
CROWD BRAKES RELEASED INDICATOR to go off and the pushbutton indicator will illuminate during a normal open gear
RED crowd brake set indicator to be illuminated. lubrication cycle and will go out when the lube cycle is
completed. If the lamp remains illuminated, an open gear
7. SWING BRAKES SET PUSHBUTTON. Depress this lubrication system fault such as a lack of lubrication or lubricant
pushbutton to set the swing brakes and prevent operation of the exists. Depressing the light recycles the lubrication system and
swing function. Activation of this control will cause the green may be used to attempt to clear the fault. In conjunction with the
SWING BRAKES RELEASED INDICATOR to go off and the illumination of this lamp, an audible alarm will also sound. If
red swing brake set indicator to be illuminated. depressing the indicator pushbutton clears the fault, it will also
clear the audible alarm.
8. CROWD BRAKE RELEASE INDICATOR/
PUSHBUTTON. This GREEN indicator will illuminate when
the crowd brakes are in the released state. 11. UPPER LUBE PUSHBUTTON/INDICATOR. This
pushbutton indicator will illuminate during a normal upper
lubrication cycle and will go out when the lube cycle is
! WARNING
DANGER completed. If the lamp remains illuminated, an upper
lubrication system fault such as a lack of lubrication or lubricant
Releasing the crowd brakes will allow the dipper exists. Depressing the light recycles the lubrication system and
handles to move, which can cause injury, death, or may be used to attempt to clear the fault. In conjunction with the
property damage. Use the crowd controls to control illumination of this lamp, an audible alarm will also sound. If
movement of the dipper handles. Watch for unex- depressing the indicator pushbutton clears the fault, it will also
pected personnel or equipment near the shovel. clear the audible alarm.
2-5
12. LOWER LUBE PUSHBUTTON/INDICATOR. This • The dipper trip function in the hoist/crowd mode and in the
pushbutton indicator will illuminate during a normal lower propel modes.
lubrication cycle and will go out when the lube cycle is
completed. If the lamp remains illuminated, a lower lubrication • The air horn in the hoist/crowd and propel modes.
system fault such as a lack of lubrication or lubricant exists.
Depressing the light recycles the lubrication system and may be This controller can perform two specific operations at one time,
used to attempt to clear the fault. In conjunction with the such as operating the dipper handles while operating the dipper
illumination of this lamp, an audible alarm will also sound. If trip mechanism or sounding the air horn.
depressing the indicator pushbutton clears the fault, it will also
clear the audible alarm. The speed at which the dipper crowds or the left propel drive
moves, is dependent on the amount the controller handle is
moved from the vertical (neutral) position.
1 3 . R E S E T P U S H B U T T O N , C O N T R O L FAULT
INDICATOR. Depressing this pushbutton will reset the fault 16. C-R (CROWD/RETRACT) LIMIT INDICATOR/
indicators on the PLC fault output modules. Another reset PUSHBUTTON. This RED indicator will illuminate and
pushbutton, having the same function, is located on the control audible alarm (17) will sound whenever the travel limits of the
cabinet door panel. The YELLOW indicator lamp will crowd/retract function have been reached. Pressing the
illuminate if a fault registers on the programmable logic pushbutton will test the indicator light and the alarm.
controller (PLC) and/or card edge lights on the fault output
17. AUDIBLE ALARM, C-R LIMIT. This audible alarm will
modules.
sound with a medium chime tone whenever the travel limits of
the crowd/retract function have been exceeded. The volume of
this alarm can be adjusted by rotating the face plate.
NOTICE 18. LUBE SYSTEM FAULT INDICATOR/PUSHBUTTON.
Any fault indication on the operator's console requires The RED indicator will illuminate and audible alarm (19) will
an immediate visual inspection of the fault indicators sound whenever the lube system goes into fault. Pressing the
on the PLC and notification of the proper maintenance pushbutton will test the indicator light and the alarm.
personal. Repairs or adjustments must be made before 19. AUDIBLE ALARM, LUBE SYSTEM FAULT. This audible
shovel operation is continued. alarm will sound with a medium tone pulsating at a fast rate
whenever there is a lube system fault. The volume of this alarm
14. RESET PUSHBUTTON, GROUND FAULT INDICATOR. can be adjusted by rotating the face plate.
Depressing this pushbutton will reset the fault indicator latching 20. BOARD SIGNAL INDICATOR/PUSHBUTTON. The
circuits. The reset button is duplicated on the auxiliary cabinet. RED indicator will illuminate and the audible alarm will sound
The YELLOW indicator will illuminate if a ground fault is when any of the boarding signal chains are pulled. These chains
present in any of the main or auxiliary field transformers. This are located at each ladder and at the rear of the mining shovel
is a fault indication only and the proper electrical maintenance under the counterweight. Pressing the pushbutton will test the
personnel should be notified and corrective action taken indicator light and the alarm.
promptly. This lamp will remain illuminated until the problem
is corrected and the indicator is reset. 21. AUDIBLE ALARM, BOARD SIGNAL. This audible alarm
will sound with a warble tone whenever any of the boarding
signal chains are pulled. These chains are located at each ladder
15. LEFT CONTROLLER. This controller (joystick) controls: and at the rear of the mining shovel under the counterweight.
The volume of this alarm can be adjusted by rotating the face
plate.
• The crowd and retract motions in the hoist/crowd mode.
22. DC MOTOR OVERLOAD INDICATOR/PUSHBUTTON.
This RED indicator will illuminate when a DC motor registers
• The left crawler propel motions in the propel mode. an overheat condition. A pulsating alarm will sound when this
2-6
01. HOUR METER
02. STOP PUSHBUTTON
03. START PUSHBUTTON/ON INDICATOR
04. CROWD INDICATOR/PUSHBUTTON
05. PROPEL INDICATOR/PUSHBUTTON 26. HOIST BRAKES RELEASE INDICATOR
06. CROWD BRAKE SET PUSHBUTTON 27. HOIST BRAKES SET INDICATOR/PUSHBUTTON
07. SWING BRAKES SET PUSHBUTTON 28. ALL BRAKES SET PUSHBUTTON
08. CROWD BRAKE RELEASE INDICATOR/PUSHBUTTON 29. AIR PRESSURE GUAGE
09. SWING BRAKES RELEASE INDICATOR/PUSHBUTTON 30. WINDSHIELD WIPER CONTROL SWITCH
10. OPEN GEAR LUBE INDICATOR/PUSHBUTTON 31. WINDSHIED WASHER PUSHBUTTON
11. UPPER LUBE INDICATOR/PUSHBUTTON 32. BLANK
12. LOWER LUBE PUSHBUTTON/INDICATOR 33. BLANK
13. RESET PUSHBUTTON, CONTROL FAULT INDICATOR 34. DIMMER SWITCH - CONSOLE LIGHTING
14. RESET PUSHBUTTON, GROUND FAULT INDICATOR 35. DIMMER SWITCH - OPERATOR’S CAB LIGHTING
15. LEFT CONTROLLER 36. COVER PLATE, RADIO
16. CROWD/RETRACT LIMIT INDICATOR/PUSHBUTTON 37. HEATER/AIR CONDITIONER CONTROL
17. AUDIBLE ALARM, CROWD/RETRACT LIMIT 38. RIGHT CONTROLLER
18. LUBE SYSTEM FAULT INDICATOR/PUSHBUTTON 39. SWITCH, CAB LIGHTS
19. AUDIBLE ALARM, LUBE SYSTEM FAULT 40. SWITCH, CONSOLE LIGHTS
20. BOARD SIGNAL INDICATOR/PUSHBUTTON 41. SWITCH, FLOOD LIGHTS
21. AUDIBLE ALARM, BOARD SIGNAL 42. SWITCH, WINDOW DEFROST CONTROL
22. DC MOTOR OVERLOAD INDICATOR/PUSHBUTTON 43. SWITCH, MACHINERY HOUSE HEATERS
23. AUDIBLE ALARM, DC MOTOR OVERLOAD 44. SWITCH, MOTOR HEATERS
24. DELAY SHUTDOWN INDICATOR/PUSHBUTTON 45. EMERGENCY STOP PUSHBUTTON
25. AUDIBLE ALARM, DELAYED SHUTDOWN
Figure 2-2. Operator’s Controls - Raised Control Console Panels
2-7
lamp is illuminated. Pressing the pushbutton will test the 27. HOIST BRAKES SET PUSHBUTTON. Depress this RED
indicator light and the alarm. pushbutton to set the hoist brakes and prevent operation of the
hoist function. Activation of this control will cause the green
HOIST BRAKES RELEASED INDICATOR to go off and the
hoist brakes set indicator will be illuminated.
NOTICE
A continual occurring thermal overload will damage 28. ALL BRAKE SET PUSHBUTTON. Use this pushbutton to
the motor(s). Thermal overloads can be caused by ei- set all motion brakes.
ther operator abuse or a mechanical/electrical prob-
29. PRESSURE GAUGE. This gauge indicates the system air
lem. Shut down the shovel, use lockout/tagout
pressure.
procedures, then, investigate and correct the problem
prior to continued shovel operation. 30. WIPER CONTROL SWITCH. Use this control to operate
the wiper. Rotate the control to the RUN position to operate the
23. AUDIBLE ALARM, DC MOTOR OVERLOAD. This windshield wiper. Rotate the control to the PARK position to
audible alarm will sound with a medium tone, medium rate turn the wiper off.
whenever any of the DC motors are in overtemperature or
overload condition. The volume of this alarm can be adjusted by 31. WINDSHIELD WASHER PUSHBUTTON. Use this
rotating the face plate. control to dispense washer solvent on the surface of the
windshield. The washer solvent pump will operate for as long
as the button is held depressed.
24. DELAY SHUTDOWN INDICATOR/PUSHBUTTON.
This RED indicator will illuminate and an audible alarm will 32. SWITCH, BLANK
sound when the shovel is about to enter a delayed shutdown
condition. A delayed shutdown will result in a shut down 30 33. SWITCH, BLANK
seconds after the alarm has sounded. The mining shovel should
be parked with the dipper placed on the ground immediately 34. SWITCH, DIMMER. This switch is used to control the
upon the sounding of this alarm. Pressing the pushbutton will intensity of the backlighting in all of the pushbuttons and
test the indicator light and the alarm. indicator labels.
35. SWITCH, DIMMER. This switch is used to control the

25. AUDIBLE ALARM, DELAYED SHUTDOWN. This operator’s cab interior lighting intensity.
audible alarm will sound with a continuous medium tone
whenever the shovel has entered a delayed shutdown. The 36. COVER PLATE, RADIO. Remove this plate to install a
volume of this alarm can be adjusted by rotating the face plate. radio, if desired.
26. HOIST BRAKES RELEASE INDICATOR/ 37. HEATER/AIR CONDITIONER CONTROL. Use this
PUSHBUTTON. This GREEN indicator will illuminate when control to operate the heater/air conditioner. Rotate the control
the hoist brakes are in the released state. to the HEAT position to operate the heater. Rotate the control to
the COOL position to operate the air conditioner. Rotate the
control to the VENT position to allow outside air to be drawn
into the operator's coop. Rotate the control to the OFF position
! WARNING
DANGER to turn off the heater/air conditioner. Regulate heating and
cooling temperatures with the use of the thermostat control
Releasing the hoist brakes will allow the dipper to knob. Located on the end of the right console.
drop, which can cause injury, death or property
damage. Use the hoist controls to control movement 38. RIGHT CONTROLLER. This controller (joystick)
of the dipper. Watch for unexpected personnel and controls:
or equipment near the shovel.
• The hoist and lower functions in the hoist/crowd mode.
Depress this pushbutton to release the hoist brakes and permit
operation of the hoist function through the use of the RIGHT • The right crawler propel motions in the propel mode.
CONTROLLER. Activation of this pushbutton will cause the
green HOIST BRAKES RELEASED INDICATOR to • The swing motions in the hoist/crowd mode and in the propel
illuminate. modes.
2-8
This controller can perform two specific operations at one time, 44. HEATER SWITCH, MOTORS. When placed in the ON
such as operating the dipper while swinging the upper. position, this switch actuates the heater strips located in the
motors as needed for specific weather conditions. Place the
The speed at which the dipper is raised or lowered, is dependent switch in the OFF position to turn off the motor heaters.
on the amount the controller handle is moved from the vertical
45. EMERGENCY STOP PUSHBUTTON. Depressing this
(neutral) position. Swing acceleration and deceleration is also
stop pushbutton shuts down the operation of the shovel, sets all
controlled by the amount of controller handle movement from
motion brakes, and removes power from the PLC outputs (110/
the vertical (neutral) position.
120VAC). This button must be manually pulled out to resume
39. LIGHT SWITCH, CAB. Use this switch to control the normal start-up procedures using the START PUSHBUTTON.
illumination of the operators cab. 46. OPERATOR'S SEAT. The operator's seat has comfort
40. LIGHT SWITCH, CONSOLE. Use this switch to control controls located under and on the front of the seat for adjusting
the illumination of the control consoles. the seat position to suit the operator.
47. PROGRAMMABLE LIMIT SWITCH (NOT SHOWN).
41. LIGHT SWITCH, FLOOD. When placed in the ON
The programmable limit switch or switches serve to control the
position, this switch turns on the exterior flood lights. Place the
operating extremes of the crowd and hoist functions. These
switch in the OFF position to turn off the exterior flood lights.
electronic controls are pre-programmed by authorized
42. SWITCH, WINDOW DEFROST. When placed in the ON personnel, and limit the extend/retract functions of the crowd
position, this switch turns on the window defroster. Place the motion, and a separate limit switch controls the raise/lower
switch in the OFF position to turn off the window defroster. functions of the hoist.
43. HEATER SWITCH, HOUSE. When placed in the ON PROGRAMMABLE MESSAGE DISPLAY (NOT SHOWN).
position, this switch actuates the heaters located in the machine The programmable message unit is a pre-programmed unit
house as needed for specific weather conditions. Place the which serves to communicate specific machine operating
switch in the OFF position to turn off the house heaters. conditions and situations to the operator.
2-9
SECTION 3
METER MODULE OPERATION
GENERAL METER SELECTOR SWITCH
This section identifies and describes the operation of the meter The meter selector switch determines which voltages and/or
module components. Each component is covered separately currents will be displayed on the meters. This switch may be
with examples of operation given where necessary. moved to any position as desired during any mode of operation.
The toggle switch determines which parameters will be
displayed by the meters. The following procedure is an example
The meter module consists of three meters, a test selector of the meter selector switch operation.
switch, and a meter switch (see Figure 3-1). The meter selector
switch has an outer range and an inner range; the toggle switch To monitor the hoist motion parameters, proceed as follows (see
at the left of this switch determines which range will be Figure 3-2):
displayed on the meters. A test jack on the panel allows one
meter to be used as a DC voltmeter for troubleshooting the
control frames. The meters directly display: field current, 48. Set the meter selector switch to the HOIST position.
armature current, armature voltage, control supply voltages and
test jack input voltages. 49. Set the toggle switch to the UP or ORANGE position.
Figure 3-1. Meter Module
3-1
1. In the RUN position, the excavator will be completely
operational, as soon as normal start-up procedures are initiated.
2. When the Test Selector switch is in the ARMATURE TEST

position only the armature circuits may be powered-up. The
motor field supplies will not be active and the motors will not
be permitted to rotate. The motor brakes will remain set even
though the brake release buttons may be pressed. be active. The
field current values can be measured on the field current meter.
NOTICE
See the Electrical Data Sheets for proper field current
values.
3. The CONTROL TEST position allows various measurements

to be taken without the armature or field supplies being
activated. The auxiliary motors, pumps, etc. will not be
energized.
4. The AUXILIARIES TEST position will permit operation of

Figure 3-2. Meter Selector all auxiliary motors and lower carbody control systems. No
power will be applied to the armature or field supplies.
50. The hoist motion parameters such as the field current,
armature current, and voltage may be read on the meters.
METERS
The same procedure can be followed to monitor SWING or
CROWD/PROPEL motion parameters by merely setting the
METER SELECTOR switch to the appropriate position. There are three meters mounted on the meter module panel (see
Figure 3-1). The function of the meters is as follows:
NOTICE
See the Electrical Data Sheets for specified voltage
and current values.
TEST SELECTOR SWITCH
The position of the Test Selector switch determines which mode

of operation the excavator is in (see Figure 3-3).
! CAUTION
DANGER
Never move the Test Selector switch from one posi-
tion to another without first pressing the STOP but- Figure 3-3. Test Selector
ton on the operator’s console.
3-2
1. The meter on the left indicates values of motor field current.
The meter scale is divided into 2 amp divisions (minor) and 10
amp divisions (major). Full scale is 150 amps (see Figure 3-4).
2. The meter in the center indicates values of motor armature

current. The meter scale is divided into 25 amp divisions
(minor) and 125 amp divisions (major). Full scale is 3000 amps
(see Figure 3-5)
3. The meter on the right side of the panel serves two functions:
A. It indicates armature voltage.
B. It indicates control voltage and test voltage values.
This meter is zero-centered, and has three scales. The top scale
is 600-0-600, the middle scale is 30-0-30 and the bottom scale
is 12-0-12 (see Figure 3-6).
Figure 3-5. Armature Current Meter
TEST JACK
The test jack on the meter module is used as the input to the
voltmeter when static testing the motion control circuit boards
(see Figure 3-7). The METER SELECTOR switch must be in
the appropriate test position; either 3 volt, 12 volt, 30 volt or 60
volt position and the toggle switch set in the UP or ORANGE
position.
Because the common lead to the meters is connected internally

only one test probe is required when making the DC voltage
measurements. To prevent damage to the foil on the circuit
boards, use test probe assembly 79Z2738-D2 when making
measurements.
Figure 3-4. Field Current Meter
The 600-0-600 volt scale is used to monitor armature motor

voltage. Depending on the position of the meter selector switch
this scale can be used to monitor any DC voltage equal to or less
than 60 VDC + or -.
The 12-0-12 volt scale is used when making measurements of

less than 12 volts DC + or -. The METER SELECTOR switch
must be in the 12VTEST position and the toggle switch must be
in the UP or ORANGE position.
The 30-0-30 volt scale can also be used to monitor any DC

voltage equal to or less than 30V DC + or -.
When the METER SELECTOR switch is in the 3 volt test

position the same 30 volt scale is used but full scale + or - is 3.0 Figure 3-6. Armature and Control Voltage Meter
volts DC.
3-3
TESTING DC SUPPLY VOLTAGES
Use the following procedure to check the +24 and -24 volt DC
supply voltages.
1. Turn the relay supply and control supply circuit breakers to

the "ON" position.
2. Set the toggle switch to the UP or ORANGE position.
3. Set the METER SELECTOR switch to the +24 volt control

supply position. The voltmeter should read approximately +24
volts DC.
4. Set the METER SELECTOR switch to the -24 volt control

supply position. The voltmeter should read approximately -24
volts DC.
NOTICE
These voltages are unregulated and may reflect a high
or low incoming power line.
5. Set the toggle switch to the down or yellow position.
Figure 3-7. Test Jack 6. Set the METER SELECTOR switch to read the ±15V DC
supply voltages for each motion frame.
3-4
SECTION 4
TROUBLESHOOTING WITH THE PLC-5/15 FAULT
INDICATORS
Table 4-1. Index - Rack 3 Indicator Lights
ADDRESS IDENTIFICATION PAGE
030-00 Ground fault main transformer Page 4-10

O30-01 Ground fault field supply Page 4-12
O30-02 Ground fault auxiliary circuits Page 4-14
O30-03 Control supply breaker fault or undervoltage fault Page 4-17
O30-04 Main supply phase fault Page 4-18
O30-05 Main transformer overcurrent fault Page 4-19
O30-06 Main transformer thermal overload Page 4-20
O30-07 Relay supply breaker fault Page 4-22
O30-10 Converter phase fault hoist #1 Page 4-23
O30-11 Converter phase fault hoist #2 Page 4-25
O30-12 Converter phase fault swing Page 4-27
O30-13 Converter phase fault crowd-propel Page 4-29
O30-14 Diverter power supply fault Page 4-31
O30-15 ±15VDC supply fault Page 4-32
O30-16 +42VDC supply fault Page 4-34
O30-17 +24VDC supply fault Page 4-35
O31-00 Door open fault converter Page 4-36
O31-01 Door open fault cap-reactor 1 Page 4-37
O31-02 Door open fault cap-reactor 2 Page 4-38
4-1
O31-03 Door open fault R.P.C. switch Page 4-39

O31-04 Door open fault auxiliary cabinet Page 4-40
O31-05 Door open fault transfer cabinet Page 4-41
O31-06 Door open fault field supply cabinet Page 4-42
O31-07 460VAC Breaker Trip Page 4-43
O31-10 Capacitor pressure bank #1 Page 4-44
O31-13 Capacitor pressure bank #1/2 Page 4-47
O31-14 Breaker open bank #1 Page 4-48
O31-17 Breaker open bank #1/2 Page 4-51
O32-00 Thermal O.L. arm swing Page 4-52
O32-01 Lube Oil Fault (2300XPB) Page 4-53
O32-02 Not used Page 4-54
O32-03 Thermal O.L. arm hoist Page 4-55
O32-04 Thermal O.L. arm crowd-propel Page 4-56
O32-05 Hoist field thermal O.L. Page 4-57
O32-06 Hoist field breaker open Page 4-58
O32-07 Hoist field off state fault Page 4-59
O32-10 Crowd-propel field thermal O.L. Page 4-60
O32-11 Crowd-propel field breaker open. Page 4-61
O32-12 Crowd-propel field off state fault Page 4-62
O32-13 Swing field thermal O.L. Page 4-63
O32-14 Swing field breaker opening Page 4-64
O32-15 Swing field off state fault Page 4-65
O32-16 Suppression breaker fault Page 4-66
O32-17 RPC off state fault Page 4-67
O33-00 Hoist control loss Page 4-68
O33-01 Hoist field loss Page 4-70
4-2
O33-02 Hoist armature overcurrent Page 4-72

O33-03 Hoist diverter system fault Page 4-74
O33-04 Hoist differential voltage fault Page 4-75
O33-05 Crowd-propel field loss Page 4-76
O33-06 Crowd-propel armature overcurrent Page 4-78
O33-07 Crowd-propel diverter system fault Page 4-80
O33-10 Swing field loss Page 4-81
O33-11 Swing armature overcurrent Page 4-83
O33-12 Swing diverter system fault Page 4-85
O33-13 Swing differential voltage fault 1 and 2 Page 4-86
O33-14 Lube PLC power fault Page 4-87
O33-15 Vibration detection Page 4-88
O33-16 Motor bearing overtemperature #1 Page 4-89
O33-17 Motor bearing overtemperature #2 Page 4-90
O34-00 Auxiliary motor fault Page 4-91
O34-01 Lube oil flow hoist fault Page 4-93
O34-02 Main air pressure fault Page 4-94
O34-03 Converter cooling fault Page 4-95
O34-04 Control cabinet fan thermal O.L. Page 4-96
O34-05 RPC cabinet fans (2) thermal O.L. Page 4-97
O34-06 Slack rope fault Page 4-98
O34-07 Lube PLC fault Page 4-99
O34-10 Boom Jacked Stage I Page 4-100
O34-11 Boom Jacked Stage II Page 4-101
O34-12 Crowd Brake Set-Up Fault Page 4-102
O34-13 Hoist Brake Set-Up Fault Page 4-103
O34-14 Hoist Brake Lost Air Pressure Page 4-104
O34-15 Swing Brake Lost Air Pressure Page 4-105
O34-16 Hoist Lower Limit Switch Page 4-106
O34-17 Swing Brake Set Up Fault Page 4-107
4-3
INTRODUCTION CONTROLLER (PLC-5/15)
This section provides the information needed to troubleshoot The Controller

the control system and interpret the indications shown on the
PLC controller. The Programmable Logic Controller (P.L.C.) used in the model
4100 machines is the PLC 5/15 by ALLEN BRADLEY. The 5/
15 processor system consists of the following components:
PROGRAMMABLE LOGIC 7. PLC 5/15 processor module. (See illustration below)
Figure 4-1. PLC-5 Processor Module
4-4
8. Power supplies. PROCESSOR SYSTEM
9. Software.
Status Indicators
The processor module has six LED status indicators. The LEDs
indicate both normal operation and error conditions of your
10. Input/output hardware, i.e.: racks, input and output modules. processor system. They are:
• FORCE (amber)
TROUBLESHOOTING PLC-5 • ADPT (green)

Table 4-2. PLC-5 Processor Troubleshooting
INDICATOR COLOR (ACTION) DESCRIPTION PROBABLE CAUSE RECOMMENDED ACTION
PROC green Processor is fully None
FAULT/RUN (steady) operational
red major fault Run-time Check major fault bit in status

(blinking) error file (element #11) or error defi-
nition. Clear fault bit, correct
problem, and return to run
mode.
red User RAM has Clear memory and reload pro-

(steady) checksum error gram.
Memory-module error Check backplane switch set-

tings and/or insert correct mem-
ory module
Check power supply and con-

off Processor is in pro- nections
gram load or test
mode or is not reciev-
ing power
PROC all Internal diagnostics have 1. Power down, reset processor,
REM I/O red failed power up.
COMM (steady) 2. Clear memory, reload pro-
gram
3. Replace EEPROM with new
program
4. Replace processor
FORCE amber Forces enabled None
(steady)
amber Forces present but not None

(blinking) enabled
off No forces present None

BATT red Battery dead Replace battery
(steady)
off Battery is good None
4-5
Table 4-2. PLC-5 Processor Troubleshooting
INDICATOR COLOR (ACTION) DESCRIPTION PROBABLE CAUSE RECOMMENDED ACTION
ADPT Processor is in adapter None
mode
off
Processor is in scan- None
ner mode
WHEN PROCESSOR IS IN SCANNER MODE
REM I/O green Active remote I/O link None
(steady)
Remote I/O link fault
red Wiring, adapter Check all connections, check
(steady) module(s) adapter
Partial remote module(s)
I/O link fault
green/red One or more remote I/O chas- check status bits in
(blinking) sis faulted status file (element #7) to iden-
tify faulted chassis number;
check
wiring, adapter module(s),
No remote I/O power supply
selected
off None
Active remote I/O link

WHEN PROCESSOR IS IN ADAPTER MODE
REM I/O green Remove I/O active None
(steady) and host processor is
in program load or test
green mode None
(blinking)
red Bad communication Duplicate station address Correct station address

(steady) with selected
host processor
green Check connections
(sporadic) No communication
with host processor
off None
COMM green Processor is transmit- None

(blinking rapidly or ting or recieving on
slowly) peer link
red Duplicate station address Correct station address

(steady dull color) selected
off
No communication on None
peer link
4-6
• REM I/O ACTIVE/FAULT (green/red) 4. Place the new battery in the holder. Make sure the positive (+)
end of the battery contacts the positive (+) end of the battery
• COMM ACTIVE/FAULT (green/red) holder; the negative (-) end of the battery must contact the
negative (-) end of the battery holder.
• PROC RUN/FAULT (green/red)
5. Secure the battery cover with the thumb screws.
• BATT (red)
How to Dispose of the Battery
After reading this section you should know how to troubleshoot
your PLC-5/15 processor system using the processor module’s Follow these guidelines when you dispose of the processor’s
LED status indicators. battery:
1. Do not incinerate or expose the battery to high temperatures.
INSTALLING AND REPLACING THE 2. Do not solder the battery or leads; the battery could explode.
PROCESSOR MODULE’S HARDWARE 3. Do not open, puncture, or crush the battery. The battery could
explode and toxic, corrosive, and flammable chemicals could be
How to Replace the Processor’s Battery exposed.
4. Do not charge the battery. An explosion might result or the
The PLC-5/15 processor is a solid-state device. There is cell might overheat and cause burns.
virtually no maintenance required for this processor module.
However, we recommend that you replace the internal lithium 5. Do not short positive or negative terminals together. The
battery every two years when the BATT status indicator is red. battery will heat up.
To replace a battery do the following: How to Install the Memory Modules

1. Make sure the processor is powered while replacing the You install the memory modules in the same fashion. The
battery if you do not want to lose your program. EEPROM module has two plastic tracks on the bottom that
2. Loosen the thumb screws that secure the battery cover. correspond to grooves in the processor memory-module slot;
the CMOS RAM modules have three plastic tracks on the
3. Remove the battery from the holder. bottom.
Figure 4-2. Inserting a Memory Module
4-7
To install an EEPROM module. 5. Slide the processor into the I/O chassis and secure the I/O
chassis latches.
1. Turn off the incoming power source.
6. Turn on system power.
2. Lift the latch of the I/O chassis that holds your processor and
remove it from the chassis.
How to Remove the Memory Modules
3. Place the processor on a clean flat surface with the bottom of
the module facing you.
Repeat steps one through three in the EEPROM module install
4. Position the memory module in the memory-module slot with procedure or one through five in the CMOS RAM install
its label facing upward. Insert and press firmly (Figure 4-2). procedure. Insert a coin into the memory-module slot so that it
Table 4-3. PLC-5 2-Slot Addressing Mode
4-8
engages the lip on the memory module. Carefully rotate the coin upward to remove the memory module from its slot. Grasp and
remove the memory module.
Fuse Blown Output Modules
Each PLC module has eight internal fuses that protect the modules circuitry from external overloads.
If a "Fuse blown" light is illuminated on any output module, one or more internal fuses is blown.
POSSIBLE CAUSES SOLUTIONS - PROCEDURES
Unloaded Outputs
! WARNING
DANGER
A blown fuse in any unloaded output module such as used in
Hazardous Voltage can cause severe injury or the indicator rack will result in a non-operating fault indicator
death. Never insert or remove a module from or on that output module.
into a rack while power is on. Failure to follow
this rule could result in damage to the module
circuitry and/or injury to personnel.
Externally Loaded Outputs To Replace A Blown Fuse

1. Turn power off.
A blown fuse in any loaded output module will result in a
non-operating fault indicator and a non-operating output 2. Pivot wiring arm away from module.
signal.
3. Remove module from rack and remove protective cover
An examination of the external circuits should be made to from module.
determine why the fuse failed. 4. Replace blown fuse.
5. Reinstall protective cover.
6. Insert module into rack.
7. Reconnect pivot arm to module. Apply power.
4-9
Ground Fault Main TransformerO30-00
The ground fault detection circuitry monitors the main transformer neutral for any grounds. In the event a ground condition exists
on either secondary circuit of the main transformer the following indicator lamps will be lit: O30-00 and the light in Operators Coop.
Troubleshooting information will also be displayed on the P.M.D. units.
! CAUTION
DANGER ! WARNING
DANGER
When the 30 second shutdown alarm sounds, the Hazardous Voltage can cause severe injury or
machine should be immediately parked in a safe death. Always disconnect power to the electrical
manner with the dipper positioned on the circuits before attempting any work in these ar-
ground. eas. Consult your machine schematics for power
disconnect points.
NOTICE NOTICE
1. To isolate the area of a ground fault it is recom- 1. Do not used a megger to check components in any
mended to open certain circuits by disconnecting electrical cabinet. Meggers should only be used for
wires, cables, bus bars, or opening circuit breakers. checking disconnected motors, cables, or transform-
ers.
2. When opening the RPC circuits it will be neces-
sary to disable the shutdown circuitry to test in the 2. TEST for main transformer ground faults only in
armature test position. "Armature Test" position of the TEST selector
switch.
3. To clear the ground fault lights, press the reset
button on the control cabinet or in the operators 3. Ground fault circuitry and identification can be
coop. checked by pushing the "ground fault main test"
pushbutton.
4. The ground fault relay, located in the Aux. Cabi-
net must be manually reset by depressing the reset Some machines may have separate AC and DC
button on the relay itself. ground fault detection and indication. If your ma-
chine is so equipped, the Programmable message
display will indicate AC or DC ground faults
4-10
GND
FLT POSSIBLE CAUSES SOLUTIONS - PROCEDURES
TYPE
DC Ground in cables to DC motors. Open connections at the converter and at motors.
Megger each cable to ground. Minimum resistance is

500,000 ohms.
DC Ground in DC motors. Open connections to DC motors. Megger each motor
connection point to ground. Minimum resistance is 2
Megohms.
AC Ground in overhead bus bar assembly. Inspect and repair accordingly.
AC Defective varistors in converter cabinet. Check if varistors are blown or shorted to ground. A fuse
fault should occur also.
DC Internal short on diverter capacitor. Disconnect leads on suspect capacitor and check for
grounds with an ohmmeter.
DC Grounds in C/P - H/P transfer cabinet, cabling. Check all connections, cables bus bars and contactors.
Correct accordingly.
DC Grounded grid resistor in diverter circuit. Examine each grid resistor for each motion. Disconnect
leads and check each resistor for grounds.
AC Defective ground fault components. Check all components in these circuits with an ohmmeter.
DC Ground only occurs when machine is in propel. Check propel motor cabling low voltage collectors.
DC Ground only occurs when hoist brake release button is Isolate hoist motors by opening leads at converter or transfer
pressed. cabinet start converter in "Armature Test" not in RUN.
DC Ground only occurs when crowd brake release button is Isolate crowd motor by opening motor leads in transfer
pressed. cabinet. Start converter in armature test not in run. If fault is
clear, problem is in crowd motor or in the cabling to the
motor. Megger these components.
DC Ground only occurs when swing brake release button is Swing motors or cables are grounded. Disconnect and
pressed. megger accordingly.
AC Shorted components in suppression cabinet. Open one suppression circuit breaker at a time. While in the
armature test position clear the fault by pressing the ground
fault reset pushbutton. If fault stays clear with one or both
breakers open problem is in the suppression cabinet
components or wiring.
AC Ground in RPC circuits. Check for any chafed cables in the RPC cabinet. Also, for
any flex bus bar shunts that may be touching ground.
Check for any capacitors that may be shorted internally to

ground.
Check for any signs of arcing on RPC reactors to ground, or

broken reactor mounts.
4-11
Ground Fault Field Supply O30-01
The field supply voltages are taken from a separate winding on the auxiliary transformer. The ground fault detection circuitry will
initiate the appropriate indication on the PLC rack and in the operators coop. Troubleshooting information will also be displayed on
the P.M.D. units.
See schematics page 2.
Fault indicator O30-01 will be illuminated.
! WARNING
DANGER NOTICE
Hazardous Voltage can cause severe injury or 1. Do not use a megger to check components in any
death. Always disconnect power to the electrical electrical cabinet. Meggers should only be used for
circuits before attempting to work in these areas. checking disconnected motors, cables, etc.
Consult your machine schematics for proper dis-
connect points. 2. To isolate the area of a ground it may be necessary
to open circuit breakers, wires, cables, etc. Remem-
ber to reconnect properly when completed.
3. Ground fault circuitry and indication can be

checked by pushing the "ground fault field test"
pushbutton.
4. To clear a ground fault indication press the reset

button on the control cabinet or in the operators
coop.
5. The ground fault relay located in the Aux. Cabi-

net must be manually reset by depressing the reset
button on the relay itself.
4-12
Ground in hoist, swing, crowd, or propel motor(s) or cables. Open each field circuit breaker one at a time to determine
which motion is at fault.
Remember to press the fault light reset pushbutton after each

breaker is opened.
Also, check for chafed cables in transfer cabinet. After determining which motion is at fault, isolate the cabling
and motor. Megger the field windings and the cables from the
field supply cabinet to the motors.
Defective or grounded R-C suppression circuits in field Replace defective components and or wiring.
supply cabinet.
4-13
Ground Fault Auxiliary Circuits O30-02
The ground fault detection circuitry for the auxiliary transformer will initiate the appropriate indication on the PLC rack and in the
operators coop. See schematics page 2. Manual shutdown is recommended. Troubleshooting information will also be displayed on
the P.M.D. units.
! WARNING
DANGER NOTICE
Hazardous Voltage can cause severe injury or 1. Do not use a megger to check components in any
death. electrical cabinet. Meggers should only be used for
checking disconnected motors, cables or transformers.
Always disconnect power to the electrical circuits
before attempting to work in these areas. Consult 2. To isolate the area of a ground it may be necessary
your machine schematics for proper disconnect to open circuit breakers, wires, cables, etc. Remember
points. to reconnect properly when completed.
3. To clear a ground fault indication press the reset but-

! CAUTION
DANGER ton on the control cabinet or in the operators coop.
If your machine is equipped with optional ground 4. Ground fault circuitry and indication can be
fault shutdown circuits, an alarm will sound 30 sec- checked by pushing the "ground fault auxiliary test"
onds before the shutdown occurs. pushbutton.
The machine should be safely parked with the dip- 5. The ground fault relay located in the Aux. Cabinet
per on the ground before the shutdown occurs. must be manually reset by depressing the reset button
on the relay itself.
4-14
Optional Circuit
An optional ground fault monitoring circuit is available to supervise the auxiliary circuits.
Its basic operation is to monitor for any leakage current to ground in the auxiliary motor circuits. In the event a ground exists the
module will illuminate a ground fault lamp and shunt trip their associated circuit breaker.
The following troubleshooting chart will cover these topics:
Grounds in:
Lighting circuits
100 VDC supply
Duplex receptacles
Auto lube heaters
Air lube heaters
Lower 120 VAC supply
Upper motor heaters
Relay circuits
Zip Lift hoist
Air conditioning unit
Operators coop heater receptacles
Welder receptacles
Air compressor
Machinery house heaters
Auxiliary motor starter circuits
Power supply circuits
Ground in lighting circuits. Open circuit breakers providing power to the cab lights and
flood lights one at a time. Make sure the flood light switch in
the operators coop is in the on position. Clear fault using fault
reset pushbutton.
Ground in 100 VDC supply or associated circuitry. Open DCSB circuit breaker, check circuits in the transfer
cabinet also. See page 24 of machine schematics.
Ground in duplex receptacles or circuits-loads. Open DRB1 thru 5 one at a time while clearing fault each time.
Unplug any loads that might be on these lines. See page 24 of
machine schematics.
Ground in the auto lube heater. Open LDB circuit breaker. Check air compressor drain valve
heaters and thermostat. See page 24 of machine schematics.
Ground in the air systems heaters. Check compressor drain valve heaters and thermostat. See page
27 of machine schematics.
Ground in the 120 VAC supply. Open MB circuit breaker. Check heaters, switches, wiring, low
voltage collectors for right and left propel motor heaters and
brake solenoid heaters. See page 24 and 26 of machine
schematics.
4-15
Ground in upper motor heaters. Open motor heater circuit breakers. Check heaters and wiring
on heaters for the hoist swing and crowd DC motors. Also,
check wiring from the motor to the heater contactor MHC. See
page 27 of machine schematics.
Ground in relay circuits. Open RSB circuit breaker. If ground clears, close RSB and open
RSCB. If ground clears, problem is in the wiring between these
two breakers.
If ground is present, open either breaker and check circuits

between RSCB breaker and MCR contacts. See schematics.
Ground in Zip Lift hoist-(near lube room). Open ZLB circuit breaker. Clear ground indication. Disconnect
hoist repair accordingly. Also, check heaters and defrosters in
operators coop.
Ground in air conditioning unit. Open AHB circuit breaker. Clear ground-repair accordingly.
Ground in heater receptacles in upper or operators coop. Open HB circuit breaker. Clear ground-repair accordingly.
Ground in welder receptacles. Open WSB circuit breaker. Clear ground-repair accordingly.
Ground in air compressor motor or controls. Open ACB circuit breaker. Clear ground-repair accordingly.
Ground in machinery house heaters. Open MHB1 and/or MHB2 circuit breakers. If ground clears,
problem is in heaters or wiring to them.
Ground in auxiliary motor starter circuits. Open each auxiliary motor starter circuit breaker one at a time
while resetting the ground fault indicator each time to
determine where the fault is.
Make sure the ground fault relay in the Aux. Cabinet is reset
each time also.
Ground in power supply circuits. Open SB circuit breaker. If fault clears, problem is in this area.
Close SB and open CSB breaker. If fault occurs, problem is in
the wiring between these two breakers.
Open CSB and check for grounds on the 3 phase wiring to the
primaries of all the power supply transformers.
It is unlikely that a ground on the secondary of these power

supply transformers will cause a ground fault indication
because of the relativity high impedance of the transformers.
4-16
Control Supply Breaker Fault or Undervoltage Fault O30-03
The undervoltage relay monitors the 240 VAC supply voltage and will initiate an immediate machine shutdown if this voltage dips
more than 20 percent below its nominal value. A tripped or manually opened control supply breaker will also trigger this fault.
See schematics page 28, line 19 and 10.
! WARNING
DANGER ! DANGER
Hazardous Voltage can cause severe injury or Hazardous Voltage will cause severe injury or
death. death. Remove incoming high line power from ma-
chine before working in any high voltage areas.
Open RCSB and CSB circuit breakers before
working on these circuits.
Open control supply circuit breaker. Close the breaker.
High voltage line dip. Try to restart the machine.
Blown fuse on auxiliary transformer primary. Replace fuse after checking the transformer windings for
shorted turns, etc.
Defective 3 phase bridge rectifier feeding the UV relay. Replace bridge rectifier.
Loss of 115 VAC supply to the UV relay. Restore 115 VAC supply. Check the voltage supply transformer.
Defective relay or module. Replace complete module assembly.
Defective wiring to module. Repair accordingly.
Module out of adjustment.
Open control supply breaker. Close breaker.
4-17
Main Supply Phase Fault O30-04
The main supply phase fault relay verifies the phasing of the main power to the excavator by monitoring the auxiliary transformer
secondary supply CS1-CS2-CS3. Troubleshooting information will also be displayed on the P.M.D. units.
See schematics pages 2 and 28.
! WARNING
DANGER ! WARNING
DANGER
Hazardous Voltage will cause severe injury or Hazardous Voltage can cause severe injury or
death. Open High Voltage Disconnect switch before death. Open CSB and RCSB circuit breakers be-
working on any high voltage circuits. fore working in the control cabinet.
Trailing cable connections of improper phase rotation. Reconnect cable for proper phase rotation.
Control supply circuit breaker is open. Close breaker(s). Check for reason it was tripped.
Defective phase sensing relay. Replace relay.
Single phasing of relay. Check the AC voltage to the P.S.R.
Blown use on primary of auxiliary transformer. Replace fuse after checking transformer windings for shorts.
Phase rotation of auxiliary wiring changed. Reconnect properly.
4-18
Main Transformer Overcurrent Fault O30-05
The main transformer overcurrent fault relay QTTM will initiate an instantaneous machine shutdown if the primary current should
exceed a certain level. Relay contacts MTOAR will change the trip level of QTTM for more sensitivity during running conditions.
See schematics page 1, line 19.
! DANGER ! WARNING
DANGER
Hazardous Voltage will cause severe injury or Hazardous Voltage can cause severe injury or
death. Open air disconnect switch before working death. Open ACCB and CSB breakers before
in high voltage areas. working in the auxiliary cabinet.
Excessive amounts of current being drawn by the main Shorted turns in primary windings. Excessive loading of the
transformer. secondary windings due to phase-phase shorts, shorted
thyristors in RPC or converter.
Open wires from C.T.’s to machinery ground or to QTTM relay. Correct accordingly. The C.T.’s in the main transformer may
Open T.O.L elements. have been damaged due to high voltage if secondary wires were
loose or off.
Open burden resistor across rectifier. Replace resistor with the exact ohmic value. See schematics
page 1.
Defective bridge rectifier. Replace bridge rectifier.
Loss of 115 VAC supply to QTTM relay module. Restore voltage supply.
4-19
Main Transformer Thermal Overload Fault O30-06
The thermal overload condition of the main transformer is monitored by relay TTMT thermal elements and its contacts. In the event
a thermal overload condition exists this relay will initiate a 30 second delayed shutdown. Troubleshooting information will also be
displayed on the P.M.D. units.
! WARNING
DANGER ! DANGER
Hazardous Voltage can cause severe injury or Hazardous Voltage will cause severe injury or
death. Open ACCB and CSB circuit breakers be- death. Open high voltage air disconnect switch be-
fore working in auxiliary cabinet. fore working in main transformer.
Excessive amounts of current being drawn by the main

transformer. ! CAUTION
DANGER
When the 30 second shutdown alarm sounds the
machine should be safely parked with the dipper
positioned on the ground.
Check for: Shorted turns on the main transformer secondary

windings. Shorted thyristors in the RPC circuits. Improper
firing pulses from RPC modules. See Section 7 for procedures
on testing RPC modules/firing pulses.
Shorted diode(s) in bridge rectifier associated with QTTM Replace rectifier.

relay.
4-20
Improperly connected main transformer taps causing an Correct accordingly.

unbalance in the secondaries.
A voltmeter could be used to measure the main transformer
secondary voltage levels. Start machine in armature test.
Non-functioning RPC system. Correct accordingly. Monitor RPC indicator panel for proper
L.E.D. indication. See Section VII in this manual.
The main transformer is also equipped with an internal

temperature gauge. If the main transformer is equipped with
cooling fans, this device will energize the fans at approximately
150° C. If the temperature continues to approximately 190°, this
device will initiate a machine shutdown.
4-21
Relay Supply Breaker Fault O30-07
In the event the (RSB) relay supply breaker trips or is manually opened, the machine will be immediately shut down.
Indicator O30-07 will be illuminated.
! WARNING
DANGER ! WARNING
DANGER
Hazardous voltage can cause severe injury or Hazardous voltage can cause severe injury or
death. death.
Open MB main breaker circuits before working on the RSB Be absolutely sure the test selector is in the "Control Test"
circuits. position before proceeding with work in these circuits.
Tripped RSB breaker. Defective components, see page 24 of schematics and

continue on to the pages listed on line 45 of page 31.
4-22
Converter Phase Fault Hoist #1 O30-10
The phase monitor relay will initiate an instantaneous machine shutdown if the three phase voltages feeding the hoist #1 converter
become unbalanced. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER ! WARNING
DANGER
Hazardous Voltage can cause severe injury or Hazardous Voltage can cause severe injury or
death. death.
Open CSB and RCSB circuit breakers before Be absolutely sure the test selector switch is in the
working in the control or converter cabinet. "CONTROL TEST" position before proceeding to
test the firing pulses.
Blown phase monitor leg fuse. Defective phase monitor relay or varistors causing the fuse
failure.
Blown main leg fuse for Hoist #1 converter. Shorted thyristors in hoist #1 converter. Locate shorted device
with an ohmmeter.
Further testing of thyristors can be done with the thyristor tester.

See Section #10 for procedures.
Improper firing pulses to the hoist #1 converter. See Section 6

for procedures on testing the firing pulses.
Loss of current feedback signal from converter to control cards. Check condition of the wiring and current transformers in the
current feedback circuit.
4-23
This will result in an overcurrent condition in the converters and Check bridge rectifier and resistors in this circuit as well as the
ultimately cause fuse failure or diverter trips. thermal overload elements.
Defective firing pulse generator circuit cards or defective See Section 6 for procedures on checking current feedback with
current regulator circuit card. an oscilloscope.
Arcing between bus bars in converter cabinet or in overhead bus See Section 6 for procedures on checking voltage values and
bar area. waveforms for these circuit cards.
Check for signs of arcing or the presence of foreign materials

(tools) on bus bars.
4-24
Converter Phase Fault Hoist #2 O30-11
! WARNING
DANGER ! WARNING
DANGER
death. Open CSB and RCSB circuit breakers be- death.
fore working in the control or converter cabinet.
Be absolutely sure the test selector switch is in the
"CONTROL TEST" position before proceeding to
failure.
Blown main leg fuse for hoist #2 converter. Shorted thyristors in hoist #2 converter. Locate shorted device
with an ohmmeter.

Improper firing pulses to the hoist #2 converter. See Section 6

for procedures on testing the firing pulses.
4-25
Defective firing pulse generator circuit cards or defective See Section 6 for procedures on checking voltage values and
current regulator circuit card. waveforms for these circuit cards.
Arcing between bus bars in converter cabinet or in overhead bus Check for signs of arcing or the presence of foreign materials
bar area. (tools) on bus bars.
4-26
Converter Phase Fault Swing O30-12
! WARNING
DANGER ! WARNING
DANGER
death. death.
failure.
Blown main leg fuse for swing converter. Shorted thyristors in swing converter. Locate shorted device
with an ohmmeter.

Improper firing pulses to the swing converter. See Section 6 for

procedures on testing the firing pulses.
4-27
See Section 6 for procedures on checking current feedback with

an oscilloscope.
Defective firing pulse generator circuit cards or defective See Section 6 for procedures on checking voltage values and
current regulator circuit card. waveforms for these circuit cards.
4-28
Converter Phase Fault Crowd Propel O30-13
! WARNING
DANGER ! WARNING
DANGER
death. death.
failure.
Blown main leg fuse for C/P converter. Shorted thyristors in C/P converter. Locate shorted device with
an ohmmeter.

Improper firing pulses to the C/P converter. See Section 6 for

procedures on testing the firing pulses.
4-29
This will result in an overcurrent condition in the converters and Check bridge rectifier and resistor in this circuit as well as the
Defective firing pulse generator circuit cards or defective See Section 6 for procedures on checking current feedback with
current regulator circuit card. an oscilloscope.
See Section 6 for procedures on checking voltage values and

waveforms for these circuit cards.
4-30
Diverter Power Supply Fault O30-14
The diverter power supply provides +28 VDC power to the hoist, swing and crowd diverter modules. These modules are located in
the center sections of the converter cabinet as is this power supply. A failure of this power supply will result in an instantaneous
machine shutdown. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER ! WARNING
DANGER
death. Be sure the test selector switch is in the death. Use extreme caution when measuring volt-
"CONTROL TEST" position before working in ages in converter cabinet.
converter cabinet.
Failure of diverter power supply. Before replacing power supply remove leads 30451 and 28342
from this unit. Turn CSB breaker on. Measure output voltage,
+28 VDC.
If +28 VDC is not present but the input voltage of 240 VAC is
ok-replace module.
Failure of a diverter module(s) causing +28 VDC from power Open leads 30451 and 28342 on each diverter module-check to
supply to fold back to zero volts. see if voltage returns at power supply. Replace defective
diverter module. The above leads may be daisy-chained so after
opening leads from module, tie multiples together.
4-31
±15 VDC Supply Fault O30-15
The ±VDC power supply provides power to all of the circuit boards in all of the motion control frames and R.P.C. This supply uses
a self-check circuit and as long as the ±15VDC is present on the check terminals, the internal relay will remain closed. If either the
positive or the negative 15VDC is lost, these contacts will open and initiate an instantaneous machine shut down. Troubleshooting
information will also be displayed on the P.M.D. units.
! WARNING
DANGER ! WARNING
DANGER
death. death.
Open CSB circuit breaker before attempting to do Use extreme caution when measuring any voltage
any work on this power supply. levels on the ±15 VDC or ±24 VDC power supplies.
Failed fuses on power supply.

NOTICE
The ±15 VDC power supply is located behind the mo-
tion control frames at the very bottom.
Open CSB breaker, replace failed fuse(s). Open leads 28401

and 28421. Replace fuses. Check voltage at output terminals
with a voltmeter. If ok, reconnect wires.
4-32
Continued fuse failure. If fuses continue to fail when wires 28401 and 28421 are
reconnected problem is in the load side of the circuits such as
the circuit boards the supply feeds.
With wires 28401 and 28421 opened ±15 VDC is not present. Check for ±24 VDC on input terminals. If 24 VDC is not
present, restore this supply.
4-33
42VDC Supply Fault O30-16
The ±42 volt DC power supply provides power to the firing pulse amplifier circuit cards YXU126-2. In the event of a failure of the
+42 volt supply a monitoring rely, (MR 42) will become deenergized and will initiate an instantaneous machine shutdown.
! WARNING
DANGER ! WARNING
DANGER
death. death.
Open CSB or SB circuit breakers before working Use extreme caution when making voltage mea-
on these circuits. surements in this cabinet.
Failure of +42 volt DC power supply. Using a voltmeter, check for +42 VDC on wires 29091 and
28342 on the bridge rectifier. If no voltage is present or
voltage is low, check for balanced AC voltage on 3 phase
input to bridge.
Synchronizing pulse transformer failure. A lack of proper AC voltage to the bridge would indicate a
synchronized transformer failure.
Defective MR 42 relay. Replace relay.
Series resistor shorted on MR 42 coil. Replace resistor and relay.
4-34
24 Volt Relay Supply Fault O30-17
The 24 volt DC relay supply provides power for the 24 VDC input cards in the PLC. In the event of a failure of the 24V power supply
the PLC will initiate an instantaneous machine shutdown. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER ! WARNING
DANGER
death. death.
Open CSB or SB circuit breakers before working Use extreme caution when making voltage mea-
on these circuits. surements in this cabinet.
Overloading of 24 volt circuit causing voltage value to be less Open wires 29261 and 29262 at power supply. Monitor
than nominal value. voltage with voltmeter. This supply should read slightly
higher than 24 volts when it is unloaded. The actual value
depends on the incoming line.
Voltage is zero or close to it. Defective components in the circuit. Replace accordingly.
Check for shorted power supply capacitor. Open winding on
transformer.
4-35
Door Open Fault-Converter Cabinet O31-00
Whenever the machine is in a "started" mode of operation be it in run, arm, control, auxiliary or field test position of the selector
switch, the opening of a door on the converter cabinet will result in an instantaneous machine shutdown. Troubleshooting
! WARNING
DANGER
Hazardous Voltage can cause severe injury or
death.
Open RCSB circuit breaker on the control cabinet

before working on the door interlock circuits.
Door opened during operation. Close door securely-check that latching devices of door work
properly.
Defective or misadjusted door interlock switch. Adjust switch so it operates properly or replace it.
Loose wiring in door interlock circuit. Loose wiring will act as if a door was opened. Check the wiring
at all connection points.
4-36
Door Open Fault-Cap-Reactor-Cabinet #1 O31-01
switch, the opening of a door on the cap-reactor cabinet will result in an instantaneous machine shutdown. Troubleshooting
! WARNING
DANGER
death.

properly.
4-37
Door Open Fault-Cap-Reactor Cabinet #2 O31-02
switch, the opening of a door on the cap-reactor cabinet will result in an instantaneous machine shutdown. Troubleshooting
! WARNING
DANGER
death.
Open RCSB circuit breaker on the control cabi-

net before working on the door interlock circuits.
Door opened during operation. Close door securely-check that hatching devices of door
work properly.
Loose wiring in door interlock circuit. Loose wiring will act as if a door was opened. Check the
wiring at all connection points.
4-38
Door Open Fault-Cap-Switch Cabinet O31-03
switch, the opening of a door on the cap-switch cabinet will result in an instantaneous machine shutdown. Troubleshooting
! WARNING
DANGER
death.

properly.
4-39
Door Open Fault-Auxiliary Cabinet O31-04
switch, the opening of a door on the auxiliary cabinet will result in an instantaneous machine shutdown. Opening of either door will
also shunt trip ACCB breaker. See schematics page 45, line 12. Troubleshooting information will also be displayed on the P.M.D.
units.
! WARNING
DANGER
death.
Open RCSB circuit breaker on the control cabi-

net before working on the door interlock circuits.
properly.
Loose wiring in door interlock circuit. Loose wiring will act as if a door was opened. Check the
wiring at all connection points.
4-40
Door Open Fault-Transfer Cabinet O31-05
Whenever the machine is in a "started" mode of operating be it in run, arm, control, auxiliary or field test position of the selector
switch, the opening of a door on the transfer cabinet will result in an instantaneous machine shutdown. See schematics page 45, line
8. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER
death.

properly.
Loose wiring in door interlock circuits. Loose wiring will act as if a door was opened. Check the wiring
4-41
Door Open Fault-Field Supply Cabinet O31-06
switch, the opening of a door on the field supply cabinet will result in an instantaneous machine shutdown. Opening of this door will
also cause the field breakers to shunt trip. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER
death.

properly.
4-42
460VAC Aux. Breaker Trip O31-07
In the event the auxiliary main breaker trips, a signal will initiate a 30 second delayed shutdown.
Troubleshooting information will also be displayed on the Programmable Message Display.
Tripped 460VAC main breaker. Door interlock wiring is defective causing the breaker to
shunt trip.
Short on secondary wiring and/or components connected to

this breaker. See page 17 of schematics.
4-43
Capacitor Pressure Fault Bank #1 O31-10
The capacitor pressure switches used on the RPC capacitors are of a normally closed configuration. If a capacitor develops a fault
internally an abnormal amount of pressure could build up and open the contacts of these switches. This in turn will result in an
instantaneous machine shutdown. Troubleshooting information will also be displayed on the P.M.D. units.
See schematics page 46 for pressure switch configuration.
! WARNING
DANGER ! WARNING
DANGER
death. death.
Make sure all circuit breakers in all of the RPC Be sure that the voltage on all capacitors has de-
cabinets are open, as well as RCSB circuit break- creased to zero before working on the RPC cir-
er in the control cabinet. cuits. Test with voltmeter on 1200 VAC scale. If
any voltage is present, bleed it off to ground
through a 500 ohm resistor.
Defective RPC capacitor causing internal overpressure. Replace capacitor. The open pressure switch can be found by
using an ohmmeter and checking for continuity on wiring
found on page 46 of the schematics. Some capacitors that
have an overpressure condition may look slightly bulged on
the sides.
Defective pressure switch. Replace switch. See service bulletins EAC-7 for replacement
part number and procedures.
Loose or broken wiring from pressure switches to PLC. Correct accordingly.
4-44
internally an abnormal amount of pressure will build up and open the contacts of these switches. This in turn will result in an
! WARNING
DANGER ! WARNING
DANGER
death. death.
Make sure all circuit breakers in all of the RPC cab- Be sure that the voltage on all capacitors has de-
inets are open, as well as RCSB circuit breaker in creased to zero before working on the RPC circuits.
the control cabinet. Test with voltmeter on 1200 VAC scale. If any volt-
age is present, bleed it off to ground through a 500
ohm resistor.
using an ohmmeter and checking for continuity on wiring found
on page 46 of the schematics. Some capacitors that have an
overpressure condition may look slightly bulged on the sides.
Defective pressure switch. Replace switch-see service bulletin EAC-7 for replacement part
no. and procedures.
4-45
! WARNING
DANGER ! WARNING
DANGER
death. death.
cabinets are open, as well as RCSB circuit break- creased to zero before working on the RPC cir-
er in the control cabinet. cuits. Test with voltmeter on 1200 VAC scale. If
any voltage is present, bleed it off to ground
through a 500 ohm resistor.
using an ohmmeter and checking for continuity on wiring
found on page 46 of the schematics. Some capacitors that
have an overpressure condition may look slightly bulged on
the sides.
Defective pressure switch. Replace switch-see service bulletin EAC-7 for replacement
part no. and procedures.
4-46
Capacitor Pressure Fault Bank 1/2 O31-13
! WARNING
DANGER ! WARNING
DANGER
death. death.
cabinets are open, as well as RCSB circuit breaker creased to zero before working on the RPC circuits.
in the control cabinet. Test with voltmeter on 1200 VAC scale. If any volt-
age is present, bleed it off to ground through a 500
ohm resistor.
using an ohmmeter and checking for continuity on wiring found
on page 46 of the schematics. Some capacitors that have an
overpressure condition may look slightly bulged on the sides.
Defective pressure switch. Replace switch. See service bulletin EAC-7 for replacement
part number and procedures.
Loose or broken wiring on the pressure switches to the PLC. Correct accordingly.
4-47
RPC Circuit Breaker Open Bank #1 O31-14
The RPC circuits are equipped with large circuit breakers which when tripped will initiate the sounding of an alarm and a 30 second
delayed shutdown of the machine. Troubleshooting information will also be displayed on the P.M.D. units.
See your machine schematics page 44.
! WARNING
DANGER ! WARNING
DANGER
death. death.
in the control cabinet.
Test with voltmeter on 1200 VAC scale. If any volt-
age is present bleed it off to ground through a 500
ohm resistor.
Defective RPC firing module causing misfiring of the thyristor. See section in this manual for procedures testing RPC modules.
Shorted diode or thyristor. A shorted device will allow this phase of the RPC system to be
on all of the time. This may result in a thermal trip of a circuit
breaker. It will also cause an unbalanced secondary line which
may cause other faults.
Loose connections causing arcing. Arcing may cause the RPC modules to misfire. Correct arcing
problem accordingly.
Shorted turns on reactor. Replace reactor.
4-48
! WARNING
DANGER ! WARNING
DANGER
death. death.
ohm resistor.
Defective RPC firing module causing misfiring of the thyristor. See Section 7 in this manual for procedures on testing the RPC
modules.
4-49
! WARNING
DANGER ! WARNING
DANGER
death. death.
ohm resistor.
modules.
4-50
RPC Circuit Breaker Open Bank 1/2 O31-17
! WARNING
DANGER ! WARNING
DANGER
death. death.
ohm resistor.
modules.
4-51
Thermal Overload Armature Swing O32-00
The thermal overload elements are electrically located in the armature current feedback circuits. If this signal is held on for an
extended period of time the thermal elements will heat up causing a set of contacts to open.
See schematics pages 9, 10, and 43. When these contacts open an alarm in the operators coop will sound and the T.O.L. light will
be illuminated. Manual shutdown is required. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER NOTICE
Hazardous Voltage can cause severe injury or Do not stall the DC motors for longer than 5 seconds
death. without a cooling off period of 3 to 5 minutes with mo-
tor blowers running.
Open CSB and RCSB circuit breakers before
Motion brake dragging. Check adjustment of brakes. Correct accordingly. Also check
for proper air pressure to brake systems.
Improper field current value, causing less motor torque which Check for proper value of field current.
could result in long duty cycles.
Defective or improper value of the thermal overload element. Improper values of the T.O.L. elements will cause improper
heating of the bi-metal contacts causing a fault. See parts
manual for proper part per motion.
4-52
Lube Oil Flow Swing Fault - 2300XPB ONLY O32-01
If the lube systems for the swing transmissions become inoperative electrically or mechanically to a point where the oil flow switches
become closed the machine will be automatically sequenced into a 30 second delayed shutdown. Troubleshooting information will
also be displayed on the P.M.D. units.
! WARNING
DANGER ! CAUTION
DANGER
Hazardous Voltage can cause severe injury or When the 30 second shutdown alarm sounds the
death. machine should be immediately parked in a safe
manner with the dipper positioned on the ground.
Open ACCB, RCSB and CSB circuit breakers be-
fore working on these circuits.
Loss of oil flow from either swing lube pump systems. Check to see if oil filter status pointer indicates a clogged oil
filter, if so replace oil filter.
Broken coupling between motor and lube pump. Replace coupling.
Faulty lube oil flow switch. Replace switch.
Defective motor or motor starter assembly. If the motor is tripped off line because of overcurrent etc., the
auxiliary motor fault light would be illuminated.
Low level of oil in the transmission. Correct accordingly.
Shovel may be operated on a grade too steep, causing the oil in Correct accordingly.
the gear box to flow to one side.
4-53
Available O32-02
4-54
Thermal Overload Armature Hoist O32-03
See schematics pages 6, 7, 8 and 43.
When these contacts open an alarm in the operators coop will sound and the T.O.L. light will be illuminated. Manual shutdown is
required. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER NOTICE
Improper field current value. Check for proper value of field current.
4-55
Thermal Overload Armature C/P O32-04
See schematics pages 11, 12 and 43. When these contacts open an alarm in the operators coop will sound and the T.O.L. light will
be illuminated. Manual shutdown is required. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER NOTICE
Improper field current value. Check for proper value of field current.
4-56
Hoist Field Thermal Overload O32-05
The hoist field overload circuit monitors the field current through both hoist motors. If this current becomes excessive a set of T.O.L.
contacts will open and initiate a 30 second delayed automatic machine shutdown. Troubleshooting information will also be displayed
on the P.M.D. units.
! WARNING
DANGER ! CAUTION
DANGER
Open all field circuit breakers. Also, open CSB and
RCSB breakers before working on these circuits.
Malfunctioning circuit boards in the hoist field frame, causing Check circuit boards using procedures in this manual. See
the field current to be excessive. Section 6, also monitor value of field current using the onboard
meter module.
Loss of current feedback to circuit boards in control frame. This Restore current feedback. This signal can be monitored by
will allow the system to turn full on with no current regulation. following the procedures in section 6 of this manual.
Check feedback components, i.e. bridge rectifier, resistors,

wiring, etc.
Loss of AC voltage to the field transductor. Check AC volts on wires 29241 and 29242. See schematics
pages 13 and 29.
Defective control cabinet fan. Replace fan.
4-57
Hoist Field Breaker Open O32-06
In the event the hoist field circuit breaker trips to its open position, the machine will be immediately and automatically shutdown.
! WARNING
DANGER
death.
Open all field circuit breakers. Also open CSB and

RSCB breakers before working on these circuits.
Shorted field thyristor module. Check for a shorted thyristor using an ohmmeter. Note that
there are two thyristors per module.
Defective thyristor firing pulse from circuit cards. Check field firing pulses with an oscilloscope. See Section 6 for
procedures and waveforms.
Shunt trip of breaker. All field breakers will automatically trip if the field supply side
of the control cabinet door is opened. A malfunctioning door
interlock switch will also cause the breakers to be tripped.
4-58
Hoist Field Off State Fault O32-07
If the field current for the hoist motors becomes active when the machine is in its OFF state (shutdown) but all circuit breakers are
on, the minimum field relay will become energized. This action will initiate a shunt trip of the hoist field circuit breaker.
! WARNING
DANGER
death.

Malfunction of hoist field circuit card(s). See Section 6 for procedures on testing each card in the hoist
field control frame.
If the above described situation occurs after the trailing cable With improper phasing, the machine will not start. Phasing of
was changed it is probable that phasing of the high voltage the trailing cable must be returned to the rotation prior to the
cable was reversed when reinstalled. change.
Improper phasing upsets the generation of firing pulses from

the firing pulse generator card.
4-59
C/P Field Thermal Overload O32-10
The C/P field overload circuit monitors the field current through the C/P motors. If this current becomes excessive a set of TOL
! WARNING
DANGER ! CAUTION
DANGER
Malfunctioning circuit board in the C/P field circuits, causing Check circuit boards using procedures in this manual. See
the field current to be excessive. Section 6, also monitor value of field current using the onboard
meter module.

wiring, etc.
page 15 and 29.
4-60
C/P Field Breaker Open O32-11
In the event the C/P field circuit breaker trips to its open position, the machine will be immediately and automatically shutdown.
! WARNING
DANGER
death.

Shorted field thyristor-diode module. Check for a shorted thyristor using an ohmmeter. Note that
there is one diode and one thyristor per module.
of the control cabinet door is opened.
A malfunctioning door interlock switch will also cause the

breakers to be tripped.
4-61
C/P Field Off State Fault O32-12
If the field current for the C/P motors becomes active when the machine is in its OFF state (shutdown) but all circuit breakers are
on, the minimum field relay will become energized. This action will initiate a shunt trip of the C/P field circuit breaker.
! WARNING
DANGER
death.

Malfunction of C/P field circuit card. See Section 6 for procedures on testing each card in the C/P
was changed it is probable that phasing of the high voltage the trailing cable must be returned to the rotation, prior to the

4-62
Swing Field Thermal Overload O32-13
The swing field overload circuit monitors the field current through both swing motors. If this current becomes excessive a set of TOL
! WARNING
DANGER ! CAUTION
DANGER
Malfunctioning circuit boards in the swing field frame, causing Check circuit boards using procedures in this manual. See
the field current to be excessive. Section 6. Also, monitor value of field current using the
onboard meter module.

wiring, etc.
page 14 and 29.
4-63
Swing Field Breaker Open O32-14
In the event the swing field circuit breaker trips to its open position, the machine will be immediately and automatically shutdown.
! WARNING
DANGER
death.

Shorted field thyristor-diode module. Check for a shorted thyristor using an ohmmeter. Note that
there is one diode and one thyristor per module.
of the control cabinet door is opened.
A malfunctioning door interlock switch will also cause the

breakers to be tripped.
4-64
Swing Field Off State Fault O32-15
If the field current for the swing motors becomes active when the machine is in its OFF state (shutdown) but all circuit breakers are
on, the minimum field relay will become energized. This action will initiate a shunt trip of the swing field circuit breaker.
! WARNING
DANGER
death.

Malfunction of swing field circuit card. See Section 6 for procedures on testing each card in the swing
was changed it is probable that phasing of the high voltage the trailing cable must be returned to the rotation prior to the

4-65
Suppression Breaker Fault O32-16
If a suppression circuit breaker trips the machine will automatically and immediately shutdown. Troubleshooting information will
See schematics pages 3, 44 and 62.
! WARNING
DANGER
death.
Open both suppression circuit breakers, S/SB and

S2SB before working on these circuits.
Shorted capacitor(s) in the suppression circuits. Replace defective capacitor(s). Locate by using an ohmmeter.
Shorted wiring in this cabinet. Correct accordingly.
4-66
RPC Off State Fault O32-17
The RPC off state fault will prevent the machine from being started up if there is a faulty RPC circuit board or a false request for
compensation. Troubleshooting information will also be displayed on the P.M.D. units.
Defective RPC circuit board(s). Check: Measuring Amp, level detectors, interface circuit per
Section 7.
Defective KVAR transducer. Replace transducer.
4-67
Hoist Control Loss O33-00
The hoist control loss circuit card monitors various electrical parameters of the hoist control system. In the event these parameters
become unbalanced or non-existent this circuit board will initiate an immediate and automatic machine shutdown. Troubleshooting
Improperly set hoist motor brakes, allowing motor rotation Adjust hoist motor brake to proper setting.
without apply power.
Loss of voltage feedback signal.

! CAUTION
DANGER
Do not remove hoist control loss monitor board. If
Vfb is not present and monitor board is removed,
the system could turn full on.
Check 115 VAC supply to voltage isolator. Check for voltage

feedback signal on voltage regulator card test point TP18. If not
present, replace voltage isolator and check its AC supplies for
115 VAC.
Improperly adjusted circuit board settings. See Section 6 in this manual for potentiometer and switch
setting.
Defective circuit card. Voltage Regulator, Current Regulator, Replace one card at time to determine possible dynamic fault on
Adapter Cord, Blocking unit, Hoist Control Monitor. circuit board.
Improper values of motor voltage and/or motor current. Reset motor voltage and current to proper values.
4-68
Loss of current feedback signal. If current feedback signal is Check for Ifb signal at test point TP 6 on the current regulator
lost, there may also be an overcurrent condition with an circuit board. Check all of the wiring and connections in the
indication of hoist overcurrent. current feedback circuits. Check the bridge rectifier. Check for
open wires on hoist bridge current transformers. Check for any
loose cannon connector on hoist control frame.
Loss of "control voltage" from current regulator card. Set selector switch to CONTROL TEST position. Start the
system, press the hoist brake RELEASE pushbutton on the
operators console. Move hoist controller to full lower, measure
+8 volts DC at test point TP 17 on current regulator circuit
board. If not present, replace current regulator circuit board.
4-69
Hoist Field Loss O33-01
The hoist motion motor field current is continuously monitored by relay MFRH. In the event that the field current drops below a
certain level. This minimum field relay will initiate an immediate and automatic shutdown of the machine. Troubleshooting
! WARNING
DANGER
death.
OPEN FIELD circuit breakers. Also, open CSB

and RCSB before working on these circuits.
Hoist field circuit breaker is tripped. The hoist field circuit Try to close breaker. If it trips again, remove all power from the
breaker indicator O32-06 will also be illuminated. control cabinet and check for any shorted thyristors.
Loss of 115 VAC supply to hoist field transductor. Restore voltage accordingly. See schematics page 29.
Defective MFRH relay. Replace relay.
Open motor field circuit. Check all field cables for secure connections, pay close
attention to hoist motor connections. Check hoist field overload
element. See schematics page 13.
Defective diode bridge in hoist field current feedback loop. Replace diode bridge rectifier. If this bridge is open, no current
feedback will be present, therefore there will be no voltage to
energize relay MFRH.
Defective transductor. Replace transductor.
4-70
Defective circuit board in the hoist field control frame. Check all circuit boards per Section 6 in this manual.
Also, check for loose cannon connectors on hoist field and

armature control frames.
Open wiring between diode bridge and MFRH relay. Correct accordingly.
4-71
Hoist Armature Overcurrent O33-02
The hoist armature overcurrent protection is provided by the hoist diverter module. If the hoist system current feedback signal
exceeds a given value, the diverter module will initiate an immediate and automatic machine shutdown.
! WARNING
DANGER
death.

working on the hoist circuits. Be sure the test selec-
tor switch is in the "CONTROL TEST" position
while testing.
Overcurrent condition due to misfired converter thyristors. Check all firing pulses to both hoist converters. See Section 6
for procedures and waveforms.
Shorted thyristors in hoist converters. Use an ohmmeter to locate a shorted thyristor.
Replace with proper type.
Shorted diodes in the current feedback rectifier-see page 8. Check rectifier diodes with an ohmmeter. Replace rectifier if
necessary.
4-72
Loss of current feedback signal to control cards. Restart machine in the "Armature Test" position and monitor
the current feedback signal on test point TP 6 of the current
regulator card with a brush recorder. This signal must always be
positive and will increase with the movements of the operators
controller.
This signal should never exceed +10 VDC.
If the current feedback signal is not present, check all

components and wiring in this circuitry. See Section 10 for
information on operation of chart recorders.
Defective diverter firing circuit board (located near diverter Check the diverter SCR firing circuit board for proper pulse.
SCR’s) causing misfire of diverter SCR. See Section 8 in this manual. If firing pulses are not proper,
replace circuit assembly.
Shorted thyristor in diverter circuit. Locate and replace the shorted device. In the event a diverter
SCR shorts, a voltage will be applied to the diverter grid
resistor. This voltage will be monitored by diverter voltage
sensing relays which will also initiate a shutdown, however this
type of shutdown will be indicated by indicator O33-03 being
illuminated.
A defective diverter module. Check output signals of diverter module. See Section 8 in this
manual. Replace diverter module.
Improper trip setting on the diverter module. Reset the trip setting on the diverter module. See Section 8 in
this manual.
Defective diverter current sensor. Replace sensor.
Improper stall current settings. Reset hoist stall current setting.
4-73
Hoist Diverter System Fault O33-03
The diverter protection relays in the Hoist #1 and #2 converter circuits will become energized if a voltage is present across the large
diverter grid resistors. The machine will be immediately and automatically shutdown. Troubleshooting information will also be
! WARNING
DANGER
death.

working on the hoist circuits. Be sure the test selec-
tor switch is in the "Control Test" position while
testing.
sensing relays which will initiate a shutdown.
Defective voltage sensing relay(s). Replace voltage sensing relay. Also check the zener diodes in
this circuit.
4-74
Hoist Differential Voltage Fault O33-04
The hoist differential voltage module monitors the voltage applied to each hoist motor. If there is a difference of more than 135 VDC
between the hoist motors the module will initiate an immediate and automatic machine shutdown. Troubleshooting information will
! WARNING
DANGER NOTICE
Hazardous Voltage can cause severe injury or After a thorough mechanical inspection is completed
death. and all discrepancies corrected, a voltage check of
each hoist motor should be made by connecting a volt-
Use extreme caution when testing for different voltmeter across each motor at the differential voltage
age levels. module input terminals, 1-2-3-4. Two voltmeters
should be used and the hoist system run at a constant
Open RCSB and CSB circuit breakers before speed.
working on the hoist circuits.
Broken motor coupling, shaft or gearing. Repair accordingly.
Defective module. Replace module after monitoring the difference in hoist motor
voltage.
Open wiring between the hoist motors and the module. Repair accordingly.
Ground fault in any DC circuit can also cause this indication. Check for grounds in the armature motion systems and correct
accordingly.
4-75
Crowd Propel Field Loss O33-05
The Crowd-Propel motion motor field current is continuously monitored by relay MFRC. In the event that the field current drops
below a certain level, this minimum, field relay will initiate an immediate and automatic shutdown of the machine. Troubleshooting
! WARNING
DANGER
death.
Open field circuit breakers. Also, open CSB and

C-P field circuit breaker is tripped. Try to close breaker. If it trips again, remove all power from the
control cabinet and check for any shorted thyristor/diode
The C-P field circuit breaker indicator O32-11 will also be modules.
illuminated.
Loss of 115 VAC supply to C-P field transductor. Restore voltage accordingly. See schematics page 29.
Defective MFRC relay. Replace relay.
4-76
Open motor field circuit. Check all field cables for secure connections. Pay close
attention to the contactors in the C-P transfer cabinet and crowd
or propel motors.
Check the C-P field overload element.
Defective diode bridge in the CP field current feedback loop. Replace diode bridge rectifier. If this bridge is open, no current
energize relay MFRC.
Defective C-P field. Semi-converter circuit board, or defective Check these two circuit boards per Section 6 of this manual.
pulse amplifier circuit board.
Also, check for loose cannon connectors on the field frame.
Open wiring between diode bridge and MFRC relay. Correct accordingly.
4-77
Crowd Propel Armature Overcurrent Fault O33-06
The C-P armature overcurrent protection is provided by the C-P diverter module. If the C-P system current feedback signal exceeds
a given value, the diverter module will initiate an immediate and automatic machine shutdown. Troubleshooting information will
See schematic page 12, line 9.
! WARNING
DANGER
death.
Open RCSB and CSB breakers before working on

the C-P circuits. Be sure the test selector switch is
in the "CONTROL TEST" position while testing.
Overcurrent condition due to misfired converter thyristors. Check all firing pulses to the C-P converter. See Section 6 for
Shorted thyristors in C-P converter. Use an ohmmeter to locate a shorted thyristor. Replace with
proper type.
Shorted diodes in the current feedback rectifier. See page 12. Check rectifier diodes with an ohmmeter. Replace rectifier if
necessary.
4-78
the current feedback signal on test point TP 6 of the current
controller.
This signal should never exceed +10 VDC. If the current

feedback signal is not present, check all components and wiring
in this circuitry.
illuminated.
this manual.
Improper stall current settings. Reset C-P stall current setting.
4-79
Crowd Propel Diverter System Fault O33-07
The diverter protection relay in the C-P converter circuit will become energized if a voltage is present across the large grid resistor
in the diverter circuit. The machine will be immediately and automatically shutdown. Troubleshooting information will also be
! WARNING
DANGER
death.

working on the C-P circuits. Be sure the test selec-
tor switch is in the "CONTROL TEST" position
while testing.
Shorted thyristor in the diverter circuit. Locate and replace the shorted device. In the event a diverter
thyristor shorts, a voltage will be applied to the diverter grid
resistor. This voltage will be monitored by the diverter voltage
sensing relay which will initiate a shutdown.
Defective voltage sensing relay. Replace relay-also check the zener diodes in this circuit.
Defective diverter firing circuit board (located near the diverter Check the diverter firing circuit board for proper pulse. See
SCR’s) causing misfire of the diverter SCR. Section 8 in this manual. If the firing pulse is not proper replace
the circuit assembly.
4-80
Swing Field Loss O33-10
The swing motion field current is continuously monitored by relay MFRS. In the event that the field current drops below a certain
level, this minimum field relay will initiate an immediate and automatic shutdown of the machine. Troubleshooting information will
! WARNING
DANGER
death.
Open field circuit breakers also open CSB and

Swing field circuit breaker is tripped. Try to close breaker. If it trips again, remove all power from the
control cabinet and check for any shorted thyristor/diode
The swing field circuit breaker indicator O32-14 will also be modules.
illuminated.
Loss of 115 VAC supply to swing field transductor. Restore voltage accordingly. See schematics page 29.
Defective MFRS relay. Replace relay.
4-81
Open motor field circuits. Check all field cables for secure connections.
Pay close attention to the connections to and inside the swing

motors.
Check the swing field thermal overload element. See

schematics page 14.
Defective diode bridge in the swing field current feedback loop. Replace diode bridge rectifier. If this bridge is open, no current
energize relay MFRS.
Defective swing field semi-converter circuit board or defective Check these two circuit boards per Section 6 of this manual.
pulse amplifier circuit board. Also check for loose cannon connectors on the field frame.
Open wiring between diode bridge and MFRS relay. Correct accordingly.
4-82
Swing Armature Overcurrent Fault O33-11
The swing armature overcurrent protection is provided by the swing diverter module. If the swing system current feedback signal
exceeds a given value, the diverter module will initiate an immediate and automatic machine shutdown. Troubleshooting information
will also be displayed on the P.M.D. units.
! WARNING
DANGER
death.
Open RCSB and CSB breakers before working on

the swing circuits. Be sure the test selector switch is
in the "CONTROL TEST" position while testing.
Overcurrent condition due to misfired thyristors in the swing Check all firing pulses to the swing converter. See Section 6 for
converter. procedures and waveforms.
Shorted thyristor(s) in swing converter. Use an ohmmeter to locate a shorted thyristor. Replace with
proper type.
Shorted diodes in the current feedback rectifier. See page 10. Check rectifier diodes with an ohmmeter. Replace rectifier if
necessary.
4-83
the current feedback signal on test point TP6 of the current
controller.
This signal should never exceed +10 VDC.
If the current feedback signal is not present, check all

components and wiring in this circuitry.
illuminated.
this manual.
Improper stall current settings. Reset swing stall current setting.
4-84
Swing Diverter System Fault O33-12
The diverter protection relay in the swing converter circuit will become energized if a voltage is present across the large grid resistor
in the diverter circuit. The machine will be immediately and automatically shutdown. Troubleshooting information will also be
! WARNING
DANGER
death.

working on the swing circuits. Be sure the test se-
lector switch is in the "CONTROL TEST" position
while testing.
Shorted thyristor in the diverter circuit. Locate and replace the shorted device. In the event a diverter
thyristor shorts, a voltage will be applied to the diverter grid
resistor. This voltage will be monitored by the diverter voltage
sensing relay which will initiate a shutdown.
Defective voltage sensing relay. Replace relay-also check the zener diodes in this circuit.
Defective diverter firing circuit board (located near the diverter Check the diverter firing circuit board for proper pulse. See
SCR’s, causing misfire of the diverter SCR.) Section 8 in this manual. If the firing pulse is not proper replace
the circuit assembly.
4-85
1&2 Swing Differential Voltage Fault O33-13
The swing differential voltage module monitors the voltage applied to each swing motor. If there is a difference of more than 135
VDC between the swing motors, the module will initiate an immediate and automatic machine shutdown. Troubleshooting
! WARNING
DANGER NOTICE
Hazardous Voltage can cause severe injury or After a thorough mechanical inspection is completed
death. and all discrepancies corrected, a voltage check of
each swing motor should be made by connecting a
Use extreme caution when testing for different volt- voltmeter across each motor at the differential voltage
age levels. module input terminals, 1-2-3-4. Two voltmeters
should be used and the swing system run at a constant
Open RCSB and CSB circuit breakers before speed.
working on the swing circuits.
Broken motor coupling, shaft or gearing. Repair accordingly.
Defective module. Replace module after monitoring the difference in swing motor
voltage.
Open wiring between the motors and the module. Repair accordingly.
Ground fault in any DC circuit can also cause this indication. Check for grounds in the armature motion systems and correct
accordingly.
4-86
Lube PLC Power O33-14
The circuit breaker providing power to the lube systems PLC is located inside the lube system enclosure in the lube room. If power
is interrupted to the lube PLC, a 30 second delayed shutdown will occur.
See schematics pages 24 and 26. Also, see PLC Lube Control in section 11 of this catalog.
! WARNING
DANGER ! CAUTION
DANGER
Hazardous Voltage can cause severe injury or When the 30 second shutdown alarm sounds, the
Open MB and LDB circuit breakers before work-
ing on these circuits.
Check for shorted components in the circuit such as heater Replace as required.
strips, transformer or associated wiring.
4-87
Vibration Detection Fault (Optional) O33-15
Vibration detection sensors may be installed at the request of the user. The sensors and support equipment may be installed in any
area of the machine such as gear boxes, motors, bearings, etc. either a 30 second delayed shutdown, an immediate shutdown or
simply a warning depending on the severity of the vibration or the users request.
4-88
Motor Bearing Overtemperature #1 (Optional) O33-16
Temperature sensors may be used to monitor the temperature of motors, bearings, gear boxes, etc. In the event the temperature
exceeds a pre-set limit, an alarm may be sounded, or a machine shutdown may be initiated.
4-89
Motor Bearing Overtemperature #2 (Optional) O33-17
Temperature sensors may be used to monitor the temperature of motors, bearings, gear boxes, etc. sounded, or a machine shutdown
may be initiated.
4-90
Auxiliary Motor Fault O34-00
In the event an auxiliary motor circuit breaker or thermal overload contact associated with the auxiliary motor starter assemblies
opens, the loss of an input signal to the PLC module I-06 will result in a 30 second delayed shutdown. Troubleshooting information
will also be displayed on the P.M.D. units.
See schematics pages 17, 20, 21, 22, 23 and 45.
Fault Indicator O34-00 will be illuminated.
! WARNING
DANGER NOTICE
Hazardous Voltage can cause severe injury or To locate the opened circuit breaker or T.O.L. check
death. the power on lights on the door of the auxiliary cabinet
while the machine is running. The nonilluminated
Open ACCB and RSCB circuit breakers before lamp indicates the faulted component area.
The "Press to Test" pushbutton can be used to light all
lamps to check their status if the machine is equipped
as such.
Tripped circuit breaker. Reset circuit breaker. If breaker trips again further investigation
is required.
Tripped thermal overload caused by:
Improperly sized elements Install proper elements-see parts book.
Binding of fan or rotor Repair accordingly.
Defective motor Replace motor.
Single phasing of motor Check for an open lead or T.O.L. element. Also, check circuit
breaker for defective contact tips.
4-91
Improperly adjusted house blower fan vains. Readjust to proper number specification.
Motor drawing excessive current. Check current draw and verify that against the motor data found
on the motor nameplate.
Defective motor starter assembly. Replace motor starter components.
Defective ASR1, ASR2 or PCR relays. Replace relay(s) accordingly.
Excessive binding of dipper trip latch bar dutchman. This will Correct accordingly.
cause the operator to repeatedly actuate the trip mechanism,
increasing the duty cycle to the dipper trip motor causing a The dipper trip mechanism should open a full dipper on the 1st
T.O.L. trip. attempt.
Check resistor settings on D.T. resistors.
4-92
Lube Oil Flow Hoist Fault O34-01
If the lube systems for the hoist transmission become inoperative electrically or mechanically to a point where the oil flow switches
become closed the machine will be automatically sequenced into a 30 second delayed shutdown. Troubleshooting information will
! WARNING
DANGER ! CAUTION
DANGER
Open ACCB, RCSB and CSB circuit breakers be-
Loss of oil flow from either hoist lube pump systems. Check to see if oil filter status pointer indicates a clogged oil
filter, if so replace oil filter.
Broken coupling between motor and lube pump. Replace coupling.
Faulty lube oil flow switch. Replace switch.
Defective motor or motor starter assembly. If the motor is tripped off line because of overcurrent etc., the
auxiliary motor fault light would be illuminated.
Low level of oil in the transmission. Correct accordingly.
4-93
Main Air Pressure Fault O34-02
If the air systems for the machine becomes inoperative, the main air pressure switch will close and initiate an automatic 30 second
delayed shutdown. Troubleshooting information will also be displayed on the P.M.D. units.
! WARNING
DANGER ! CAUTION
DANGER
Open ACCB, RCSB and ACB circuit breakers be-
Tripped ACB circuit breaker. Reset breaker. If breaker trips again check motor or motor
control circuits.
Defective motor control. This control is mounted on the air compressor tank-check all
components.
Defective A/C motor. Check motor windings to ground. If any phase reads to ground
replace motor.
Defective pressure switch. Replace switch.
Low air pressure in tank. Check for leaks. Check "cut in" relay set to proper cut in
pressure.
Frozen tank valve. Thaw valve. Check de-icer system.
Receiver drain timer is faulty causing continuous bleed off of Replace drain valve and/or solenoid.
air.
4-94
Converter Cooling Fault O34-03
The cooling fault thermal overload switches are located in each converter cabinet mounted on a lower thyristor heat sink. In the event
any one of these switches open the machine will automatically sequenced into a 30 second delayed shutdown. Troubleshooting
! WARNING
DANGER ! WARNING
DANGER
death. death.
Open ACCB, RCSB and CSB circuit breaker be- Set test selector switch to the "CONTROL TEST"
fore working on these circuits. position while testing.
Inadequate air flow across the heatsinks in converter cabinet Blockage of air flow across heatsinks or an accumulation of
causing temperature rise. dust on the heatsinks or sensors.
Clean properly/remove air blockage.
Fans on top of the converter cabinet operating in the wrong Rotation of fans should be such as to pull air out through the top
rotation resulting in inadequate air flow across heatsinks. of the cabinet.
Defective sensor. Replace sensor. These devices have a normally closed

temperature of 182° F (83° C) and open at 212° F (100° C).
Open wiring from sensors to PLC input card I-02. Correct accordingly.
4-95
Control Cabinet Fan Thermal Overload O34-04
The cooling fault thermal overload switch for the control cabinet components is mounted inside of the control cabinet blower
assembly. In the event of an overheat condition of this fan motor the switch will open initiating a 30 second delayed shutdown.
! WARNING
DANGER
death.
Open RSCB circuit breaker before working on

these circuits.
Defective blower motor. Replace motor fan assembly.
Single phasing of motor causing an overheated condition. Check wiring to motor.
Check phase currents to motor.
Check CCFR contact tips for single phasing.
This motor can be wired for 50HZ or 60HZ operation. Check that this motor is wired per the machine schematics. See
page 32.
4-96
R.P.C. Fans Thermal Overload O34-05
The cooling fault thermal overload switches for the RPC cabinet blowers is mounted inside of the RPC cabinet blower assembly. In
the event of an overheat condition of these fan motors the switch(s) will open initiating a 30 second delayed shutdown.
See schematics pages 32, 56, and 64.
! WARNING
DANGER
death.
Open RCSB circuit breaker before working on

these circuits.
Defective RPC blower motor. Replace motor fan assembly.
Single phasing of motor causing an overheated condition. Check wiring to motor.
Check phase currents to motor.
Check RFCR relay tips for single phasing.
These motors can be wired for 50HZ or 60HZ operation. Check that these motors are wired per the machine schematics.
See page 32.
4-97
Slack Hoist Rope Fault (Optional) O34-06
The slack hoist rope detector will initiate a hoist brake set condition in the event the hoist ropes become slack and start to loosen up
on the hoist drum. To rewind the ropes the operator must depress and hold the hoist brake release button, and operate the hoist
controller.
4-98
Lube PLC Fault O34-07
If the lube system PLC malfunctions, a 30 second delayed shut down will occur.
See schematics page 26. Also, see PLC Lube Control in section 11 of this catalog.
! WARNING
DANGER ! CAUTION
DANGER
Hazardous Voltage can cause severe injury or When the 30 second shutdown alarm sounds, the
Open MB and LDB circuit breakers before work-
ing on these circuits.
See section 11 for detailed lube system PLC troubleshooting

procedures.
4-99
Boom Jacked Stage I O34-10
The stage I boom jacking fault will occur if the boom is raised by crowd force and/or the hoist system. In the event this fault occurs,
the signal from the operator’s crowd controller will be opened in the crowd motion only. The operator should slowly reverse the
crowd controller to the retract position until the suspension cable are once again supporting the boom Information will also be given
on the Programmable Message Display. See schematics page 41.
4-100
Boom Jacked Stage II O34-11
The stage II boom jacking fault will occur if the boom is raised by force and/or the hoist system past the second stage boom limit
switch. If this occurs, the machine will automatically shut down. To correct this situation, press and hold the start pushbutton while
pressing and holding the crowd brake release pushbutton. The machine should start up and the boom should slowly lower back to
its normal position. A small amount of retract motion from the left controller may be necessary to lower the boom past the 1st stage
limit. Information will also be given on the Programmable Message Display.
4-101
Crowd Brake Set Up Fault O34-12
The crowd motion brake should set whenever the appropriate button is pressed. It should also set when the”All Brake Set “ push
button is depressed.
Indication will also be given on the Programmable Message Display.
! CAUTION
DANGER
Unexpected movement of the mining shovel and/or
mining shovels components can result in severe
personal injury or death . Set the dipper on the
ground before checking the crowd brake system.
Crowd brake did not set when set button was pressed. Defective air pressure switch located in lube room.
Possible frozen air line to crowd motor brake.
4-102
Hoist Brake Set Up Fault O34-13
The Hoist motion brake should set whenever the appropriate button is pressed. It should also set when the”All Brake Set “ push
See schematics page 39 and 40.
! CAUTION
DANGER
ground before checking the hoist brake system.
Hoist brake did not set when set button was pressed. Defective air pressure switch located in an enclosure near each
disk brake.
Possible frozen exhaust solenoid or air line.
4-103
Hoist Brakes Lost Air Pressure O34-14
If air pressure to either hoist brake is lost, the brake will set and indication will be given. The hoist motion will stop as the operator
reference signal from the controller will cease.
Information will also be given on the Programmable Message Display.
Hoist Brake sets. Loss of air pressure at brake.
Defective air pressure switch located in an enclosure near each

disk brake.
Defective Solenoid.
4-104
Swing Brake Lost Air O34-15
If air pressure to either swing brake is lost, the brake will set and indication will be given. The swing motion will stop as the operator
reference signal from the controller will cease.
Information will also be given on the Programmable Message Display.
Swing brake sets. Loss of air pressure at brake.

disk brake.
Defective Solenoid.
4-105
Hoist Lower Limit Switch O34-16
Hoist lower limit switch was tripped or slack rope was detected
Information will also be displayed on the Programmable Message Display.
Fault indicator O34-16 will illuminated.
Lower limit switch was tripped. Press and hold the hoist brake release pushbutton and slowly
raise the dipper.
4-106
Swing Brake Set Up Fault O34-17
The Swing motion brake should set whenever the appropriate button is pressed. It should also set when the”All Brake Set “ push
See schematics page 39 and 40.
! CAUTION
DANGER
ground before checking the hoist brake system.
Swing brake did not set when set button was pressed. Loss of air pressure at brake.

disk brake.
Possible frozen exhaust solenoid or air line.
4-107
SECTION 5
TROUBLESHOOTING NON-INDICATING FAULTS
Hoist Motion Faults the PLC indicators or the PMD unit. The non-indicating faults
show up primarily as hoist deficiencies detected by the operator.
Table 5-1 covers specific hoist motion faults not indicated on
TROUBLE POSSIBLE CAUSE SOLUTIONS

Hoist motion is weak in hoisting Improper armature current limit value. Set system in ARMATURE TEST posi-
power. tion and check stall current value.
Improper value of hoist field current. Check the hoist field current value while
operating the hoist motion. The fiel cur-
rent should be in the strong. value.
Improper switch and/or potentiometer Check the control frame circuit cards
settings on the hoist armature control (see Section 6)
frame circuit cards.
Hoist brake is dragging. Adjust the brakes properly. Check the air
supply to the brake solenoids.
Lowering motion is slow. Hoist motion field value is not changing Check the hoist field reference current
to low value of current. board per the static and dynamic tests in
Section 6 of this manual.
Loose FK1 cannon connector on the Tighten the cannon connector.
reae of the field control frame.
Improper hoisting speed. Defective voltage isolator. Replace voltage isolator. Check for 600
VDC on meter module while operating
hoist motion at full speed. Check voltage
feedback adjustment.
Improper operator’s controller signal to Remove the control monitor circuit board
motion control frame. and check for +15 VDC at TP-7 of the
hoist adapter circuit board when the op-
erator’s controller is at full hoisting posi-
tion. Do this in the CONTROL TEST
position.
Hoist motion or lowering motion is Any overspeed condition will be moni- Check the 115 VAC supply to the volt-
over speeding. tored by the control monitor circuit card. age isolator.
If the fault is maintained for a certain pe-
riod of time in milliseconds, the system Replace the voltage isolator.
will automatically shut down. This will be
indicated on the fault panel. Check for open wires or loose connec-
tions in the voltage feedback circuit.
Check maximum voltage feedback level

adjustments.
Table 5-1. Hoist motion fault troubleshooting
5-1
Crowd/Propel Motion Faults indicated on the PLC indicators or the PMD unit. The non-
indicating faults show up primarily as hoist deficiencies
Table 5-2 covers specific crowd/propel motion faults not detected by the operator.

Crowd/Propel motion is weak or Improper armature current value. Set system in ARMATURE TEST posi-
slow to respond. tion and check stall currents in CROWD
and/or PROPEL mode of operation.
An improper crowd/propel field current Check the crowd/propel field current val-
value. ues.
Improper switch and/or potentiometer Check the control frame circuit cards
settings on the crowd/propel armature (see Section 6)
control frame circuit cards.
Crowd/Propel brakes are dragging. Adjust the brakes properly. Check the air
Crowd/Propel motion is weak or Improper operator’s controller signal to Check the TP-7 on the crowd/propel
slow to respond. the crowd/propel frame. adapter circuit board, for the following
readings:
• +15 VDC full crowd (propel forward).
• -15 VDC full retract (propel reverse).

Loose FK1 cannon connector on the Tighten the cannon connector.
reae of the field control frame.
Crowd (retract) or propel (forward/ Defective voltage isolator. Replace voltage isolator.
reverse) speed is not symmetrical.
Propel system is lacking power. Propel field is not at proper value. Check the field circuits. (See Section 6)
Adapter circuit boards defective. Replace either the hoist or crowd adapt-
er circuit board. See circuit card test pro-
cedure in Section 6.
Table 5-2. Crowd/Propel motion fault troubleshooting
5-2
Swing Motion Faults the PLC indicators or the PMD unit. The non-indicating faults
show up primarily as hoist deficiencies detected by the operator.
Table 5-3 covers specific swing motion faults not indicated on

Swing motion is weak or slow to re- Improper armature current value. Set system in ARMATURE TEST posi-
spond. tion and check stall current value.
Improper swing field current value. Check the field current system using
static and dynamic tests. (See Section
6).
Swing motion is weak or slow to re- Improper switch and/or potentiometer Check the control frame circuit cards
spond. settings on the swing armature control (see Section 6)
frame circuit cards.
Improper operator’s controller signal to Check the TP-19 on the swing adapter
the control frame. circuit board, for the following readings:
• +15 VDC full swing right.
• -15 VDC full swing left.

Broken motor coupling to swing trans- Replace coupling or take proper correc-
mission. tive action.
Swing motor brakes are dragging. Adjust the brakes properly. Check the air
Swing motion is overspeeding. Loss of voltage feedback signal. Check the 115 VAC supply to the volt-
age isolator.
Check the wiring and connections in the

voltage feedback circuitry.
Defective voltage isolator. Replace voltage isolator.
Table 5-3. Swing motion fault troubleshooting
5-3
SECTION 6
CONTROL FRAME AND COMPONENT
2 adapter on the AC supply to the scope or an isolation

TESTING transformer to provide electrical isolation. See Section
10 for recommended oscilloscope operating procedures.
INTRODUCTION
This section covers the static and dynamic testing of
the control frames and components. The control frames
are located in the lower section of the control cabinet ! WARNING
DANGER
(See Figure 6-1).
The chassis of the oscilloscope will be at
Some of the tests in this section require the use of an the potential of the supply DC voltage.
oscilloscope. Always isolate the oscilloscope chassis Caution must be exercised when making
from the machinery ground when testing. Also, use a 3- adjustments to the instrument.
Figure 6-1. Control Frames
6-1
FIELD CONTROL FRAME Testing Components
To test the control frame components, proceed as

General follows:
This topic covers the static and dynamic testing of the ! CAUTION
DANGER
hoist field control frame components.
Never move the test selector switch to an-
other test position without first pressing
These circuits are located in the control cabinet as the STOP pushbutton in the operator’s
shown in Figure 6-1. Test each circuit using the coop.
following procedures and test data.
8. Place the test selector switch to the CONTROL TEST
position. This allows only the control portions of the
NOTICE Electrotorque system to be operational.
The voltage values given in the tables are typi- 9. Place all circuit breakers in the closed or ON
cal values. Actual voltages measured during position.
testing may vary slightly.
±15 VDC Supply

If at any time the voltage readings measured do not
correspond closely to the values given in the charts, The ±15 VDC supply is located behind the swing-out
replace the circuit board under test and repeat the test card rack assembly.
procedure for that circuit board.
To test the ±15 VDC supply, proceed as follows:
MOTOR FIELDS CONTROL FRAME
1. Place the toggle switch on the meter panel to the
down or yellow position.
121 129 137 141 149 153 157
2. Set the meter selector switch to the + and then - 15

volt hoist field position.
3. Read the + and - voltages on the meter panel

voltmeter. If the + and - volt supplies are not correct or
unobtainable check the + and - 24 volt DC supplies.
4. Place the toggle switch on the meter panel to the up

or ORANGE position.
FIRING PULSE PULSE 5. Set the meter selector switch to the 30 volt test
FIELD SWING
REFERENCE
PULSE AMP.
SEMI-
A M P. position. If a lower voltage scale is needed, set the
CURRENT GEN. YXU
REG.
YXU
126
CONV. 703 meter selector switch to the appropriate 3 volt or 12
volt position.
C/P SEMI-
CONV.
HOIST FIELDS CONTROL CROWD AND SWING

FIELDS CONTROL NOTICE
The operator’s controller or brake set-release
pushbuttons have no effect on the operation of
Figure 6-2. Hoist Field Control Frame the hoist field control frame when the test se-
lector is in the control test position.
6-2
Hoist Field Reference Circuit Board
(980H102F1).
To test the hoist field reference circuit board, proceed
as follows:
position. Press the start pushbutton. Press the hoist
brake release pushbutton and move the hoist controller
to the lowering position. While in this position, press
the hoist brake set pushbutton, then press the stop
pushbutton. This will set the polarity signal at TP-18 to
the field reference card to the the following test.
2. Remove cannon connector FK1 from the hoist field
control frame.
3. Set the meter selector switch to the 12 volt test
position.
4. Connect a test lead from the meter panel test jack to Figure 6-3. Hoist Field Pulse Generator Output
test point 16 on the field reference circuit board. Waveform
5. Connect one end of a jumper to test point 20 on the
7. Set the field breaker to its closed position. Reconnect
field reference circuit board.
wire 44121.
6. Momentarily insert the other end of the jumper into
test point 10 of the field reference circuit board. The
voltmeter should now read -5.0 VDC. Firing Pulse Generator Circuit Board
7. Momentarily insert the loose end of the jumper into
(980H76-1)
test point 7. The voltmeter should now read -10 VDC.
To test the firing pulse generator, proceed as follows:
8. Remove the meter test lead and jumper wire from
the circuit card.
NOTICE
9. Reconnect cannon connector FK1 to the hoist field
control frame. Make sure the control and relay supply circuit
breakers are in the ON position.
Current Regulator Circuit Board
(980H46-2)
To test the current regulator circuit board, proceed as
follows:
1. Set the test selector switch to FIELD TEST.
2. Open the hoist field circuit breaker and wire 44121
on PLC. See schematic page 44.
3. Insert the meter test lead into test point 17 on the
current regulator circuit board. The voltmeter should
read -9 VDC.
4. Press the STOP and then the START button in the
operator’s coop. The voltmeter should now read +8
VDC.
5. Press the STOP pushbutton in the operator’s coop.
6. Return the test selector switch to the CONTROL Figure 6-4. Pulse Amplifier Output
TEST position.
6-3
1. Check the internal power supply on the subject card
by connecting a lead from the meter module test jack to
TP 20. The meter should read -7 VDC. TP-16 should
read +7 VDC.
Set the meter selector switch to the 3 volt position, or

use an accurate digital multimeter.
2. Connect the test lead to TP 15. The meter should
read .76V at 60HZ - .56V at 50HZ. Adjust if necessary.
Set the meter selector switch to the 3 volt position.

3. Connect the test lead to TP-4, 5, 6, 8, 9 and 10. The
meter should read 3 volts at each test point.
4. If it is desired, the waveform at TP-4, 5, 6, 8, 9 and
10 may be monitored with an oscilloscope. The
waveform should be similar to that shown in Figure 6-
3. The oscilloscope settings are as follows:
Figure 6-6. Hoist Field Current (Strong Field)
A. Vertical Sensitivity = 5 volts
be similar to the photo in Figure 6-4. The oscilloscope
B. Sweep Rate = 2 milliseconds
settings for this waveform are as follows:
Testing The Pulse Amplifier 980H74-1
1. With the meter test selector switch set to the 60 volt
test position; check that the voltage at TP 1 is +42 VDC,
the voltage at TP 10 is +15 VDC. Hoist Field Thyristor Firing Pulses
2. With the meter test selector switch set to the 60 To check the hoist field thyristor firing pulses, proceed
position, check that 35 volts is present at TP 2, 4, 6, 13, as follows:
15, and 17.
1. The hoist field thyristor firing pulses are checked
3. The waveform from TP 2, 6, 13, 15, and 17 may be with an oscilloscope. Connect the scope probe and
monitored with an oscilloscope. The waveform should ground leads to the gate and cathode (white-red) leads
of each thyristor. The firing pulses should compare to
those in Figure 6-5. Use the following scope settings:
A. Amplitude = 1 volt
B. Sweep = 2 millisecond
2. Make sure the hoist field breaker is closed.
3. Set test selector switch to the FIELD TEST position.
OVov
ov 4. Start the machine. Monitor each firing pulse
observing the amplitude and width. All should be
similar.
Testing The Hoist Field Supply

This topic covers the dynamic testing of the hoist field
supply. An oscilloscope is required to perform some of
the tests. When using the oscilloscope, observe the
Figure 6-5. Thyristor Firing Pulse precautions stated in the Introduction topic on page 6-
1.
6-4
7. The hoist field current feedback signal can be
monitored by connecting an oscilloscope probe to test
point 6 on the current regulator card and the scope
probe ground to test point 20 on the same current
regulator card. The current feedback waveforms should
compare to those in Figure 6-7 and Figure 6-6. The
oscilloscope settings for these signals are as follows:
A. Amplitude = 2 volts
This completes the dynamic testing of the hoist field.
SETTINGS FOR CIRCUIT BOARD

Figure 6-7. Hoist Field Current (Weak Field)
CIRCUIT BOARD ADJUSTMENTS HOIST FIELD
To test the hoist field supply, proceed as follows: YXR 104
GAIN 6
1. Set all circuit breakers in the closed or ON position. *LIM 1 (START) T 17 ADJUST TO +8 VOLTS
2. Set the test selector switch to the FIELD TEST *LIM 2 (STOP) T 17 ADJUST TO -9 VOLTS
ADAPT 0
position.
YXU 139B-T 12 ADJUST TO .56 VOLT 50 Hz
3. Set the meter selector switch to the HOIST position. B-LMT ADJUST TO .76 VOLT 60 Hz
Be sure that toggle switch is in the up or ORANGE
Table 6-1. Settings for Circuit Board Switches and
position.
Potentiometer
4. Press the STOP and then the START pushbuttons in
the operator’s coop. SWITCHES AND POTENTIOMETERS
5. Read the hoist field current on the field current
meter. Table 6-1 is provided for the adjustment of circuit board
switches and potentiometers.
6. When testing the hoist field current in the FIELD
TEST position the value of current will more often be in
its weakened state. If not, to drive the field current
level to the weak level the following procedure should NOTICE
be followed:
Always use a small screwdriver to adjust the
A. Connect a jumper to test point 20 on the hoist field potentiometers and switches. The dial indica-
reference circuit board. tor is a slip fit on the shaft and may turn with-
B. Momentarily insert the other end of the jumper out actually rotating the adjustment shaft.
into test point 10 of the hoist field reference circuit
card.
TESTING SWING FIELD CONTROL
C. The hoist field current should now read at the lower
(IF2) level.
The swing semi-converter control system consists of a
D. The adjustment of the weak field current level can
semi-converter control circuit board and one-half of the
be made by setting the field adjusting resistor
pulse amplifier circuit board. Refer to Figure 6-1 for the
located on the current feedback panel.
location of the swing field circuit boards. The semi-
E. Consult the electrical data sheet for the specified converter consists of 3 thyristors and 3 diodes. A
value of field current. flywheel diode is also incorporated.
6-5
6. If the pulse waveforms are not as shown, replace the
semi-converter circuit board. Recheck the pulses.
! CAUTION
DANGER
Whenever the semi-converter board is re-
placed, the field current values must be
reset.
Testing The Pulse Amplifier Circuit Board

(980H73-1)
1. Check that the input signals at TP 2, 10, and 12 are
the same as monitored on TP 17, 18 and 19 of the semi-
converter card.
Figure 6-8. Swing Semi-Converter Pulse
2. Using an oscilloscope, check each firing pulse to the
Testing The Semi-Converter Board swing semi-converter thyristors. Connect the probe to
the white lead and the ground lead to the red lead.
(980H101)
1. Make sure the machine is shutdown. Place the test The waveform should be similar to the photo in Figure
selector switch to the FIELD TEST position. 6-9.
2. Open the Hoist, Crowd, and Swing field circuit Use the following oscilloscope settings:
breakers. Open wires 44121, 44141 and 44161 in the
PLC cabinet. See schematic page 44. A. Vertical Sensitivity= 1 volt
3. Start the machine (in FIELD TEST). B. Sweep Rate= 2 milliseconds
4. Using the meter module voltmeter or a digital meter,

measure the following voltages:
TP 17............ +12 VDC

TP 18............ +12 VDC
TP 19............ +12 VDC
5. The firing pulses should also be monitored with an

oscilloscope to verify the proper waveform. Connect the
oscilloscope to test points TP 17, 18, and 19 one at a
time and observe the waveform as shown in Figure 6-8.
Use the following oscilloscope settings:
Figure 6-9. Thyristor Firing Pulse (Swing Field)

B. Sweep Rate = 1 millisecond
6-6
NOTICE
Pay particular attention to the amplitude and
width of each pulse. Each pulse should be iden-
tical in width and similar in amplitude.
3. If the pulse waveforms are not proper, replace the
pulse amplifier circuit board. Recheck the pulses, if the
pulses are still not proper, suspect a faulty semi-
converter thyristor. Replace the suspect device and
recheck the pulses.
4. Press the STOP pushbutton on the operator’s
console.
5. Close all field circuit breakers. Reconnect wires
44121, 44141, and 44161.
SWING SEMI-CONVERTER SYSTEM Figure 6-11. Swing Field Residual Voltage

The following section covers dynamic testing of the
swing semi-converter system. 3. Press the START pushbutton on the operator’s
console.
Current Feedback Use the following oscilloscope settings:
1. The swing field current feedback can be monitored by A. Vertical Sensitivity = 2 volts
connecting an oscilloscope to TP 2 on Swing Semi-
Converter circuit board. B. Sweep Rate = 5 milliseconds
The current feedback waveform should be as shown in Swing Field Voltage

Figure 6-10.
2. Make sure the system test selector switch is set to Additional system checks include monitoring the swing
FIELD TEST. field voltage as follows:
1. Connect an oscilloscope across the swing flywheel
diode. Connect the probe to the cathode of the diode,
and the scope ground to the anode.
2. With the field breakers ON, observe the residual
voltage value. The waveform should resemble those
illustrated in Figure 6-11.

3. With the test selector switch in the FIELD TEST
position, press the START pushbutton on the
operator’s console.
4. The swing field voltage waveform should resemble
Figure 6-12.
Use the following oscilloscope settings.

Figure 6-10. Swing Field Current Feedback
6-7
Figure 6-12. Swing Voltage Waveform Figure 6-13. Swing Voltage Waveform with One
Thyristor Not Firing
B. Sweep Rate = 5 milliseconds 2. Open the Hoist, Crowd, and Swing field circuit
breakers. Open wires 44121, 44141 and 44161 in PLC
5. Figure 6-13 shows a waveform with one thyristor not cabinet. See schematic page 44.
firing due to a missing firing pulse or defective
thyristor.
3. Start the machine (in FIELD TEST).
The following oscilloscope settings were used:

4. Using the meter module voltmeter or a digital meter,
A. Vertical Sensitivity = 50 volts measure the following voltages:
B. Sweep Rate = 5 milliseconds TP 17........... +12 VDC

TP 18........... +12 VDC
This concludes the testing of the swing semi-converter TP 19........... +12 VDC
systems.
TESTING THE CROWD/PROPEL

FIELD CONTROL
The C/P semi-converter control system consists of a
semi-converter control circuit board and one-half of the
pulse amplifier circuit board. Refer to Figure 6-2 for the
location of the crowd/propel circuit boards. The semi-
converter consists of 3 thyristors and 3 diodes. A
flywheel diode is also incorporated.
Testing The C/P Semi-Converter Board

(980H101)
1. Make sure the machine is shut down. Place the test
selector switch to the FIELD TEST position. Figure 6-14. Crowd/Propel Semi-Converter Pulse
6-8
A. Vertical Sensitivity = 1 volt
NOTICE
Pay particular attention to the amplitude and
width of each pulse. Each pulse should be iden-
tical in width, and similar in amplitude.
3. If the pulse waveforms are not proper, replace the
pulse amplifier circuit board. Recheck the pulses. If the
pulses are still not proper, suspect a defective semi-
converter thyristor. Replace the suspect device and
recheck the pulses.
4. Press the STOP pushbutton on the operator’s
console.
5. Close all field circuit breakers. Reconnect wires
Figure 6-15. Thyrister Firing Pulse (Crowd/Propel Field) 44121, 44141, and 44161.
5. The firing pulses should also be monitored with an The Crowd/Propel Semi-Converter System
oscilloscope to verify the proper waveform. Connect the
oscilloscope to TP 17, 18 and 19 one at a time and The following topic covers dynamic testing of the
observe the waveform as shown in Figure 6-14. Crowd/Propel semi-converter system.

Current Feedback
1. The crowd/propel field current feedback can be
B. Sweep Rate = 1 millisecond monitored by connecting an oscilloscope to TP 2 on the
6. If the pulse waveforms are not as shown, replace the crowd/propel semi-converter board.
semi-converter circuit board. Recheck the pulses.
The current feedback waveform should be as shown in
Figure 6-16.
! CAUTION
DANGER
Whenever the semi-converter board is re-
placed, the field current values must be
reset.
Testing The Pulse Amplifier Circuit Board

(980H73-1)
1. Check that the input signals at TP 2, 10 and 12 are
the same as monitored on TP 17, 18 and 19 of the semi-
converter card.
2. Using an oscilloscope, check each firing pulse to the
swing semi-converter thyristors. Connect the probe to
the white lead and the ground lead to the red lead.
The waveform should be similar to the photo in Figure

6-15.
Figure 6-16. Crowd/Propel Field Current Feedback
6-9
Crowd/Propel Field Voltage
Further system checks can be done by monitoring the

Crowd/Propel field voltage.
1. Connect an oscilloscope across the crowd/propel

flywheel diode. Connect the probe to the cathode of the
diode, and the scope ground to the anode.
2. With the field breakers ON, observe the residual

voltage value. The waveform should resemble Figure 6-
17.

Figure 6-17. Crowd/Propel Field Residual Voltage
3. With the test selector switch in the FIELD TEST
Use the following oscilloscope settings: position, press the START pushbutton on the
4. The crowd/propel field voltage waveform should
B. Sweep Rate = 5 milliseconds resemble the photo in Figure 6-18.
2. Make sure the system test selector is set to the Use the following oscilloscope settings.
FIELD TEST position.
3. Press the START pushbutton on the operator’s
console. B. Sweep Rate = 5 milliseconds
Figure 6-18. Crowd/Propel Voltage Waveform Figure 6-19. Crowd/Propel Voltage Waveform With
One Thyristor Not Firing
6-10
5. Figure 6-19 is a waveform with one thyristor not Figure 6-21 illustrates the typical control system in
firing due to a missing firing pulse or defective block diagram form.
thyristor.
A. Vertical Sensitivity = 50 volts Testing Components
To test the control frame, proceed as follows:
This concludes the testing of the Crowd/Propel semi-
converter system. ! CAUTION
DANGER
Never move the test selector switch to an-
HOIST/PROPEL ARMATURE other test position without first pressing
CONTROL FRAME the STOP pushbutton in the operator’s
coop.
General 1. Place the test selector switch to the CONTROL TEST
position. This will allow only the control portions of the
This topic covers the static and dynamic testing of the Electrotorque system to be operational.
hoist/propel armature control frame components. The
H/P armature control frame circuits are located in the 2. Place all circuit breakers in the closed or ON
control cabinet as indicated in Figure 6-20. Test each position.
circuit using the following procedures and test data. 3. Press the START pushbutton in the operator’s coop.
4. Press the hoist brake RELEASE pushbutton in the
NOTICE operator’s coop.
The voltage values given in the tables are typi-
cal values. The actual voltages measured dur- ±15 VDC Regulator
ing testing may vary slightly.
The ±15 VDC supply is located behind the swing-out
If at any time the voltage readings measured do not card rack assembly.
correspond closely to the values given in the charts,
replace the circuit board under test and repeat the test To test the ±15 VDC regulator supply, proceed as
procedure for that circuit board. follows:
CARD LOCATION NUMBERS

109
113
117
121
125
129
133
137
141
145
149
153
157
Current Regulator
Voltage Regulator
Firing Pulse Amp.
Firing Pulse Amp.
Firing Pulse Amp.
Firing Pulse Amp.

Firing Pulse Gen.
Firing Pulse Gen.

Blocking Circuit
Control Monitor
Booster Circuit
Blocking Amp
Adapter H/P
Figure 6-20. Hoist/Propel Armature Control Frame Circuit Card Location and Identification
6-11
6 0 AC
Ifb +
129 133 137
• 141
••
Vc1
TP6 TP13 TP11
+ “ON” TO
••
Vfb+ - Vc2 PULSE PULSE SCRS
- TP7 Vc TP15
AMP AMP
121 125 -
BOOSTER BOOSTER
•
•
I. REF
-
+ +
TP18 TP1
-
•
146
TP1 TP17 07A
ADAPTER
V. REF
V. REG INVERTED
“OFF” TO
“I” REF PULSE SCRS
AMP
Vc Vfb Vfb+
6 0 AC
+5 V
109 TO S.D.
- 113 +10 V
117 149
• • 153
• TP1 TP8 TP15 TP16 TP2
0V
TP11
• “ON” TO
SCRS
••
CIRCUITS +5 V
- TP6 0V PULSE PULSE
CONTROL TP16 TP19 TP1
AMP AMP
MON.
BLK. AMP BLK. AMP • 0V
157
“OFF” TO
- + Hoist or Propel Reverse PULSE
Vfb = Armature Voltage Feedback SCRS
AMP
Ifb = Armature Current Feedback
V. Ref = Voltage Reference Signal
I. Ref = Current Reference Signal
Vc = Voltage Control
CONTROLLER
REFERENCE NOTE: ON BLOCKING AMP.
•
5V = BLOCK
0V = DEBLOCKED
6 0 AC
Ifb +
129 133 137
• 141
••
Vc1
TP6 TP13 TP11
+ “ON” TO
••
Vfb+ - Vc2 PULSE PULSE SCRS
+ TP7 Vc TP15
AMP AMP
121 125 +
BOOSTER BOOSTER
•
•
I. REF
- -
TP18 TP1
+
•
146
TP1 TP17 07A
ADAPTER
V. REF
V. REG INVERTED
“OFF” TO
“I” REF PULSE SCRS
AMP
Vc Vfb Vfb+
6 0 AC
0V
109 TO S.D.
+ 113 0V
117 +5 V 149
• • 153
• TP1 TP8 TP15 TP16 TP2 TP11
• “ON” TO
SCRS
CIRCUITS
+ TP6 TP16+10 V TP19 •
••
CONTROL TP1 PULSE PULSE
MON. 0V AMP AMP
BLK. AMP BLK. AMP
+5 V
157
“OFF” TO
- + Hoist or Propel Reverse PULSE
Vfb = Armature Voltage Feedback SCRS
AMP
CONTROLLER
REFERENCE NOTE: ON BLOCKING AMP.
•
5V = BLOCK
0V = DEBLOCKED
Figure 6-21. Hoist/Lower and Propel Forward/Reverse control Flow Chart With Booster System
6-12
CIRCUIT BRAKE POSITION CONTROLLER INPUT OUTPUT VOLTAGE VALUES REMARKS
BOARD SET/REL POSITION TP TP HOIST PROPEL
SET NEUTRAL 1 +24 +24 In full hoist, the
HOIST CONTROL MONITOR
REL FULL LOWER 1 +24 +24 machine should

shut down as
REL FULL LOWER 1 0 VDC 0 VDC soon as the
controller is
moved about 1/4
off center. The
machine will not
shut down in
propel.
Table 6-2. Hoist Control Monitor

REL NEUTRAL 7 0 VDC 0 VDC If using the panel
meter, make sure
HOIST/PROPEL ADAPTER
9 0 VDC 0 VDC
the toggle switch
18 -10 -10 is in the up posi-
19 +10 +10 tion and the rota-
8 0 VDC 0 VDC ry switch is in the
HOIST position.
17 0 VDC +24 If TP-17 does not
FULL HOIST 7 +15 +15 read +24 VDC in
9 +10 +10 propel, check ex-
ternal circuits.
FULL LOWER 7 -15 -15 See Schematics.
9 -10 -10
Table 6-3. Hoist/Propel Adapter

SET NEUTRAL 17 0 VDC 0 VDC
VOLTAGE REGULATOR
REL FULL HOIST 17 +10 +10

REL FULL HOIST 11 -10 -10
FULL LOWER 17 -10 -10
FULL LOWER 11 +10 +10
Table 6-4. Voltage Regulator
6-13
SET NEUTRAL 18 1 -VOLTAGE -VOLTAGE The value of volt-
REL NEUTRAL 18 1 +VOLTAGE +VOLTAGE age at TP-18 is
dependent on the
FULL HOIST 7 1 -10 -10 vintage of the
FULL HOIST 17 +8 +8 circuit board. If the
CURRENT REGULATOR
FULL LOWER 7 +10 +10 polarity does not

change, check
17 +8 +8 external wiring to
PLC. See
Schematic.
TP-6 is the current
feedback signal
test point. TP-6 will
have a positive
voltage signal 0 to
10 V when
armature current is
present.
Table 6-5. Current Regulator

REL FULL HOIST 6 -11 -11 NOTE:
When in full low-
BLOCKING CIRCUIT
REL 8 -10 -10

er, TP-9 should
REL 9 0 VDC 0 VDC be a negative
REL 15 +9 +9 voltage. Value is
REL 16 -5 -5 not critical, but
typically around
REL FULL LOWER 6 +11 +11 -4 VDC.
REL 15 -5 -5
REL 16 +9 +9
Table 6-6. Blocking Circuit
6-14
REL FULL HOIST 16 +9 +9 NOTE:
BLOCKING AMPLIFIER
REL FULL HOIST 19 -4.5 -5 TP-7 Should be

about +10 VDC.
REL FULL HOIST 2 0 VDC 0 VDC If it is 0 VDC, sus-
REL FULL HOIST 1 +5 +5 pect a faulty di-
REL FULL HOIST 16 -5 -5 verter module.
REL FULL LOWER 19 +9 +9

REL FULL LOWER 2 -5 -5
REL FULL LOWER 1 0 VDC 0 VDC
Table 6-7. Blocking Amplifier

REL NEUTRAL 15 +9 +9 2 cards, one lo-
REL NEUTRAL 4 -4.5 -5 cated in position
FIRING PULSE
GENERATOR
137, the other in

REL NEUTRAL 5 0 VDC 0 VDC position 149.
REL NEUTRAL 6 +5 +5 Check both.
REL NEUTRAL 8 -5 -5
REL NEUTRAL 9 +9 +9
REL NEUTRAL 10 -5 -5
Table 6-8. Firing Pulse Generator

REL FULL HOIST 8 -8 -8
BOOSTER CIRCUIT
13 +8 +8
15 +8 +8
SET NEUTRAL 8 +8 +8
13 -8 -8
10 -5 -5
Table 6-9. Booster Circuit
6-15
REL FULL HOIST 3 +3 +3 2 cards, one lo-
REL FULL HOIST 2 +35 +35 cated in position
141, the other in
position 153.
REL FULL HOIST 4 +35 +35 Check both
REL FULL HOIST 7 +3 +3 cards.
REL FULL HOIST 19 +3 +3 The outputs may
REL FULL HOIST 17 +35 +35 also be monitored
with an oscillo-
REL FULL HOIST 11 0 VDC 0 VDC scope. See figure
REL FULL LOWER 2 +42 +42 Figure 6-24 for
proper waveform.
FIRING PULSE AMPLIFIERS

REL FULL HOIST 2 +42 +42 2 cards, one lo-
REL FULL HOIST 4 +42 +42 cated in position
145, the other in
position 157.
REL FULL HOIST 13 +42 +42 Check both
REL FULL HOIST 15 +42 +42 cards.
REL FULL LOWER 4 +35 +35 The outputs may
REL FULL LOWER 7 +3 +3 also be monitored
with an oscillo-
REL FULL LOWER 6 +35 +35 scope. See figure
REL FULL LOWER 14 +3 +3 Figure 6-24 for
proper waveform.
REL FULL LOWER 11 0 VDC 0 VDC
Table 6-10. Firing Pulse Amplifier
6-16
CIRCUIT BOARD ADJUSTMENTS HOIST ARMATURE
QALB 214 Voltage Regulator (980H47)
GAIN 5
TIME/GAIN .5
LIM 1 Max C.W.
LIM 2 Max C.W.
SIGN. ADJUSTMENT 0
YXN 110 Blocking Circuit(980H45)

HYSTERESIS 5
PHASE LEAD 7
CURRENT LEVEL 1.5
YXR 104 Current Regulator (980H46)

GAIN 2
*LIM 1 (START) T 17 ADJUST TO +8 VOLTS
*LIM 2 (STOP) T 17 ADJUST TO -9 VOLTS
**RESPONSE Max CW
YXU 139B-T12 Pulse Generator (980H76) ADJUST TO .56 VOLTS 50Hz
B-LMT ADJUST TO .76 VOLTS 60Hz
Table 6-11. Settings For Board Switches And Potentiometers (4100A)
** 980H46F1 regulators have an adapt pot which should be set to zero.
1. Place the toggle switch on the meter panel to the 1. Check the hoist control monitor using, adapter,
down or yellow position. voltage regulator, and current regulator circuit boards.
2. Set the meter selector switch to the + and then the - 2. Press the hoist brake SET pushbutton in the
15 volt hoist armature control position. operator’s coop.
3. Read the + and - voltages on the meter panel 3. Proceed with current regulator test number 2.
voltmeter. If the + and -15 volt DC supplies are not
correct or unobtainable, check the + and -24 volt 4. Press the hoist brake RELEASE pushbutton in the
supplies. operator’s coop. Continue with the remaining tests.
4. Place the toggle switch on the meter panel to the up 5. Press the hoist brake SET pushbutton and replace
or ORANGE position. the hoist monitor circuit board. This completes the
testing of the Hoist/Propel armature control frame
5. Set the meter selector switch to the 30 volt test circuit cards.
position. If a lower voltage scale is needed, set the
meter selector switch to the appropriate 3 volt or 12
volt position. When checking the pulse amplifier cards, SETTINGS FOR CIRCUIT BOARD
the meter selector switch should be set to the 60 volt SWITCHES AND POTENTIOMETERS
test position.
Table 6-20 provides nominal settings for the
Circuit Board Tests adjustment of the hoist motion control frame circuit
board switches and potentiometers.
To test the remaining circuit boards, follow the
information given for each card test. The machine must NOTICE
be started in “CONTROL TEST”. A remote reference
box may be used to set and release the brake electrical Always use a small screwdriver to adjust the
circuits as well as changing references voltages. potentiometers and switches. The dial indica-
6-17
OSCILLOSCOPE VERTICAL MODE TRIGGER CONTROLS TIMEBASE
Model 212 or 214 Input Coup. = DC Trigger Source to CH2 Level 2 millisec/div
CH1 = 2 volt/div Slope to POSITIVE or
CH2 = 5 volt/div PRESET position
Table 6-12. Oscilloscope Settings For Thyrister Firing Checks
tor is a slip fit on the shaft and may turn with- 6. Check each of the lowering bridge thyristor firing
out actually rotating the adjustment shaft. All pulses by connecting the probe of the oscilloscope to the
settings should be marked with locking paint. white lead (gate) of the thyristor and the ground lead of
the oscilloscope to the red lead (cathode). The waveform
on the oscilloscope should be similar to the one in
Hoist Converters Figure 6-22.
The photos and illustrations in Figure 6-23 show the 7. Move the hoist controller to the full HOIST position
locations of the hoisting and lowering thyristors of the and check each of the hoist bridge thyristor firing
inboard (No. 1) and outboard (No. 2) hoist converters. pulses. The waveform should be similar to the photo in
Figure 6-22.
Checking Thyristor Firing Pulses
The thyristor firing pulses should be checked whenever NOTICE
a thyristor loss has been experienced or if the current If a thyristor firing pulse is very high in ampli-
feedback signal indicates a misfired device. tude as compared to the other devices, suspect
an open gate circuit on the thyristor itself.
To check the armature firing pulses, proceed as follows:
1. Set the test selector switch on the meter module to Use the following oscilloscope settings:
the CONTROL TEST position.
A. Amplitude = 1 volt/division
2. Remove the hoist control monitor circuit board.
3. Turn all circuit breakers to their ON position. B. Sweep Rate = 2 milliseconds/division
4. Start the machine, then press the hoist BRAKE 8. If any of the thyristor firing pulses are found to be
RELEASE pushbutton. improper, the pulses from the pulse amplifier cards
5. Move the hoist controller to the full lowering should be checked. These pulses can be monitored with
position. an oscilloscope connected to the output test points TP
2, 4, 6, 13, 15 and 16 with respect to CCOM, TP 20
(28342).
9. With the system in CONTROL TEST, machine

started, and brakes released, set the hoist controller to
the full LOWER position. Check the pulses on the pulse
amplifier card in location 145 and 157. Check the
hoisting pulses with the hoist controller in the full
HOIST position on the pulse amplifier card in location
141 and 153. The pulse amplifier signal waveform
should be similar to those shown in Figures 6-24 and 6-
25.
10. Set the oscilloscope for the pulse amplifier output

pulse in Figure 6-24 as follows:
A. Amplitude = 20 volts/division
B. Sweep Rate = 2 milliseconds/division
11. Set the oscilloscope as follows for the output pulses

Figure 6-22. Armature Thyristor Pulse shown in Figure 6-25:
6-18
Figure 6-23. Hoist Converter Location
6-19
14. If all of the waveforms from the circuit boards are
proper, replace the firing circuit assembly pulse
transformer.
DYNAMIC TESTING
Dynamic testing of the hoist motion control frame
consists of operating the motion while monitoring
various test points on the circuit cards with an
oscilloscope.
The current feedback waveform is the most informative

signal as it reflects the current waveform fed to the DC
motors. It can also indicate misfired thyristors.
Monitoring Current Feedback

Figure 6-24. Pulse Amplifier Output Pulse
To observe the current feedback signal, an oscilloscope
A. Amplitude = 20 volts/division must be connected to TP 6 on the current regulator card
12. If the pulses are not similar to the photos in Figures

6-24 and 6-25, either the amplifier board is
malfunctioning or the pulse generator is at fault.
13. To check the pulse generator card, simply monitor
the signals at test points TP 4, 5, 6, 8, 9 and 10 with an
oscilloscope. If these pulses are not similar to the photo
in Figure 6-25, replace the pulse generator card. Use
the following oscilloscope settings:
Figure 6-26. Pulse Generator Output Pulse
with the ground of the oscilloscope connected to

(CCOM) TP 20 (28342).
It is advisable to use an oscilloscope with the ‘Line

Sync’ feature to stabilize the waveform on the
oscilloscope. Also use a 3 to 2 adapter on the
oscilloscope line plug to isolate the oscilloscope chassis
from machinery ground.
1. Set the test selector switch on the meter panel to the

ARM TEST position.
2. Make sure all circuit breakers are in their ON

Figure 6-25. Pulse Amplifier Output Pulse (3 Pulses) position.
6-20
3. Start the machine and then press the hoist brake
RELEASE pushbutton.
4. While the operator slowly moves the controller in the
lowering direction, observe the waveform on the
oscilloscope. This waveform should be comparable to
the photo in Figure 6-27. The symmetry of the
waveform is more important than the amplitude of the
current feedback signal. Use the following oscilloscope
settings:
A. Amplitude = 1 volt
5. Repeat step 4, but move the controller to the

HOISTING direction. The waveform should be similar
to the photo in Figure 6-28. Once again, the most
important thing to observe is if the waveform is
symmetrical, i.e. the waveform is not unbalanced with
Figure 6-28. Armature Current Feedback (Hoisting)
small, missing, or oversized ‘humps’. Set the
oscilloscope to the following settings:
Armature Current
B. Sweep Rate = 2 milliseconds/division ! CAUTION

DANGER
6. If the waveforms are not correct, check the thyristors The motor(s) should not be run at maxi-
and thyristor firing pulses. mum stall current for more than 5 seconds
at a time. Running with stall current for
longer periods will cause localized heat-
DYNAMIC PARAMETER CHECKS ing on the commutators.
The final steps in dynamic testing are to verify the 1. Set the test selector switch to the ARMATURE TEST
maximum values of voltage and current. These position.
parameters can be checked using the following 2. Set the meter selector switch to the appropriate
procedures. motion to be checked, i.e. hoist, swing or crowd/propel.
3. Set the toggle switch in the up or ORANGE position
if it is not there.
4. Place all circuit breakers in the closed (ON) position.
5. Press the STOP and then the START button on the
6. Press the brake RELEASE pushbutton for the
motion being checked.
7. Move the appropriate controller to the full ON
position. Check the stall current value on the armature
current meter. Consult the electrical data sheets for
the proper value of the stall current.
8. Adjust the level of the current feedback in
accordance with the information provided in the
electrical data sheets.
The adjustable resistor for changing the value of the

current feedback which ultimately affects the amount
Figure 6-27. Armature Current Feedback (Lowering)
of motor current is shown in Figure 6-29. See the
6-21
condition in the lowering direction. Similarly, -10V will
FROM CURRENT TRANSFORMER
indicate a full speed (-600V) in the hoisting direction.

•
voltage feedback which ultimately affects the amount
of motor voltage is shown in Figure 6-30. See the
• schematics for resistor identification number.
•
CROWD/PROPEL ARMATURE
• INST. CONTROL FRAME
O.L.
RELAY
1 3 This topic covers the static and dynamic testing of the
•
crowd/propel armature control frame components.
These circuits are located in the control cabinet as
• • • indicated in Figure 6-31. Test each circuit using the
following procedures and test data.
CURRENT
ADJUSTING
RESISTOR
NOTICE
TO MOTION CONTROL FRAME CIRCUIT CARDS
cal values. The actual voltages measured dur-
AND METER MODULE ing testing may vary slightly.
Figure 6-29. Current Adjusting Resistor FROM DC BUS IN CONVERTER CABINET
schematics for resistor identification number on page

8, line 44.
1 2 3 4
Armature Voltage
VOLTAGE
ISOLATOR
VOLTAGE FEEDBACK.The voltage feedback signal is
directly proportional to the DC motor armature 5 6 7 8
voltages, and is therefore a useful signal for monitoring
a particular motion’s performance. The voltage VOLTAGE FEEDBACK
ADJUSTING RESISTOR
feedback signal also goes to the meter panel for easy
measurement of armature voltage during normal RUN
operation.
115 VAC
The portion of the voltage feedback signal which is used

• • •
by the armature control frame for motor SPEED
control may be monitored with an oscilloscope or chart
recorder to get a visual indication of the system’s
performance. This may be accomplished by connecting
the test instrument between test point 18 on the
voltage regulator card and test point 20 (CCOM). The TO MOTION CONTROL FRAME CIRCUIT CARDS
polarity and amplitude of this DC signal will be directly AND METER MODULE
proportional to the motor armature voltage, and
therefore, an accurate indication of motor SPEED and Figure 6-30. Voltage Feedback Adjusting Resistor
DIRECTION. will indicate a full speed (+550V)
6-22
If at any time the voltage readings measured do not To test the ±15 VDC regulator supply, proceed as
correspond closely to the values given in the charts, follows:
replace the circuit board under test and repeat the test
procedure for that circuit board. 1. Place the toggle switch on the meter panel to the
down or yellow position.
Figure 6-32 illustrates the typical control system in
block diagram form.
2. Set the meter selector switch to the + and then the -
15 volt crowd/propel armature control position.
TESTING COMPONENTS
3. Read the + and - voltages on the meter panel
To test the control frame, proceed as follows: voltmeter. If the + and -15 volt DC supplies are not
correct or unobtainable, check the + and -24 volt
! CAUTION
DANGER supplies.
Never move the test selector switch to an- 4. Place the toggle switch on the meter panel to the up
other test position without first pressing or ORANGE position.
the STOP pushbutton in the operator’s
coop. 5. Set the meter selector switch to the 30 volt test
1. Place the test selector switch to the CONTROL TEST position. If a lower voltage scale is needed, set the
position. This will allow only the control portions of the meter selector switch to the appropriate 3 volt or 12
Electrotorque system to be operational. volt position. When checking the pulse amplifier cards,
the meter selector switch should be set to the 60 volt
2. Place all circuit breakers in the closed or ON test position.
position.
3. Press the START pushbutton in the operator’s coop.
4. Press the crowd brake RELEASE pushbutton in the Circuit Board Tests
operator’s coop.
To test the remaining circuit boards, follow the
±15 VDC Regulator information given for each card test. The machine must
be started in “CONTROL TEST”. A remote reference
The ±15 VDC supply is located behind the swing-out box may be used to set and release the brake electrical
rack assembly. circuits as well as changing references voltages.

113
117
121
125
129
137
141
145
-
Current Regulator
Voltage Regulator
Firing Pulse Amp.
Firing Pulse Amp.

Firing Pulse Gen.
Blocking Circuit
Blocking Amp
Adapter
Blank
Figure 6-31. Crowd/Propel Armature Control Frame
6-23
CONTROLLER
REFERENCE
6 0 AC
Vfb = - Ifb = +
- +
#141 To
TP18 TP6
+ TP 7 TP9
+ V. REF + TP17 TP11 - I. REF - TP7 TP17
+ Vc
TP11 SCRS
-
“ON”
07A PULSE PULSE
ADAPTER V. REG I REG GEN AMP
CROWD OR PROPEL FORWARD INV “I” REF
-
TP8 TP15
+ 0V #145 To
TP16 TP2
SCRS
- 5V “OFF”
TP6 TP16 - TP19 TP1
PULSE
BLK. AMP BLK. AMP AMP
Hoist or Propel Reverse

Vfb = Armature Voltage Feedback
NOTE: ON BLOCKING AMP.

5V = BLOCK
0V = DEBLOCKED
CONTROLLER
REFERENCE
6 0 AC
Vfb = + Ifb = +
- +
#141 To
TP18 TP6
- TP 7 TP9
- V. REF - TP17 TP11 + I. REF + TP7 TP17
+ Vc
TP11 SCRS
+
“ON”
07A PULSE PULSE
RETRACT OR PROPEL REVERSE INV “I” REF
+
TP8 TP15
- 5V #145 To
TP16 TP2
SCRS
+ TP6 0V “OFF”
TP16 + TP19 TP1
PULSE
Figure 6-32. Crowd/Propel Control Flow Chart
6-24
BOARD SET/REL POSITION TP TP CROWD PROPEL
REL NEUTRAL 7 0 VDC 0 VDC
CROWD/PROPEL ADAPTER
9 0 VDC 0 VDC
18 -10 -10.5
19 +10 +10.5
16 0 VDC 0 VDC
17 0 VDC +24
FULL CROWD 7 +15 +15
9 +10 +10
FULL RETRACT 7 -15 -15
9 -10 -10
Table 6-13. Crowd/Propel Adapter

REL NEUTRAL 17 0 VDC 0 VDC
VOLTAGE REGULATOR
11 0 VDC 0 VDC
FULL CROWD 17 +10 +10
11 -10 -10
FULL RETRACT 17 -10 -10
11 +10 +10

SET NEUTRAL 18 1 -VOLTAGE -VOLTAGE The value of voltage
at TP-18 is
REL NEUTRAL 18 1 +VOLTAGE +VOLTAGE
dependent on the
FULL CROWD 7 1 -10 -10 vintage of the
CURRENT REGULATOR
circuit board. If the

polarity does not
17 +8 +8 change, check
FULL RETRACT 7 +10 +10 external wiring to
PLC. See
Schematics.
17 +8 +8 TP-6 is the current
feedback signal test
point. TP-6 will have
a positive voltage
signal 0 to 10 V when
armature current is
present.
6-25
REL FULL CROWD 6 -11 -11 NOTE:
8 -10 -10 When in full re-
BLOCKING CIRCUIT
tract, TP-9
9 0 VDC 0 VDC should be a neg-
15 +9 +9 ative voltage.
16 -5 -5 Value is not criti-
cal, but typically
FULL RETRACT 6 +11 +11 around
8 +10 +10 -4 VDC.
15 -5 -5
16 +9 +9

REL FULL CROWD 16 +9 +9 NOTE:
BLOCKING AMPLIFIER
19 -4.5 -5 TP-7 Should be

about +10 VDC.
2 0 VDC 0 VDC If it is 0 VDC, sus-
1 +5 +5 pect a faulty di-
FULL RETRACT 16 -5 -5 verter module.
19 +9 +9
2 +5 +5
1 0 VDC 0 VDC

REL NEUTRAL 15 +1.25 +1.25
4 +3 +3
FIRING PULSE
GENERATOR
5 +3 +3
6 +3 +3
8 +3 +3
9 +3 +3
10 +3 +3
6-26
BOARD SET/REL POSITION TP TP crowd PROPEL
REL FULL RETRACT 2 +42 +42 NOTE:
REL FULL RETRACT 4 +42 +42 The output test
points may be
REL FULL RETRACT 6 +42 +42
monitored with
REL FULL RETRACT 13 +42 +42 an oscilloscope.
REL FULL RETRACT 15 +42 +42 Refer to
Figure 6-35 for

proper waveform.
REL FULL CROWD 11 +5 +5
LOCATION 141

REL FULL CROWD 17 +35 +35 NOTE:
REL FULL CROWD 11 0 VDC 0 VDC The output test
points may be
monitored with
REL FULL RETRACT 4 +42 +42 an oscilloscope.
REL FULL RETRACT 6 +42 +42 Refer to
REL FULL RETRACT 13 +42 +42 Figure 6-35 for
proper waveform.

LOCATION 141

REL FULL RETRACT 11 0 VDC 0 VDC
REL FULL CROWD
REL FULL CROWD 11 0 VDC 0 VDC
6-27
QALB 214 Voltage Regulator
GAIN 5
TIME/GAIN .5
LIM 1 Max C.W.
LIM 2 Max C.W.
SIGN. ADJUSTMENT 0
YXN 110 Blocking Circuit

HYSTERESIS 5
PHASE LEAD 7
CURRENT LEVEL 1.0
YXR 104 Current Regulator

GAIN 3
**RESPONSE Max CW
YXU 139B-T12 Pulse Generator ADJUST TO .56 VOLTS 50Hz
Table 6-20. Settings For Board Switches And Potentiometers (4100)
Press the CROWD BRAKE SET pushbutton. Press the Checking Thyristor Firing Pulses
STOP pushbutton. This completes the testing of the
crowd/propel armature control frame circuit cards.
The thyristor firing pulses should be checked whenever
a thyristor loss has been experienced or if the current
feedback signal indicates a misfired device.
Settings For Circuit Board Switches and
Potentiometers To check the armature firing pulses, proceed as follows:
1. Set the test selector switch on the meter module to

Table 6-20 provides nominal settings for the the CONTROL TEST position.
adjustment of the crowd motion control frame circuit
board switches and potentiometers. 2. Turn all circuit breakers to their ON position.
3. Start the machine, then press the crowd BRAKE

RELEASE pushbutton.
NOTICE
4. Move the crowd controller to the full CROWD
Always use a small screwdriver to adjust the position.
potentiometers and switches. The dial indica-
tor is a slip fit on the shaft and may turn with- 5. Check each of the crowd bridge thyristor firing
out actually rotating the adjustment shaft. All pulses by connecting the probe of the oscilloscope to the
settings should be marked with locking paint. white lead (gate) of the thyristor and the ground lead of
Figure 6-34.
Crowd Converter
6. Move the crowd controller to the full RETRACT
position and check each of the hoist bridge thyristor
The photos and illustrations in Figure 6-33 show the firing pulses. The waveform should be similar to the
locations of the Crowd/Retract thyristors. photo in Figure 6-34
6-28
Figure 6-34. Armature Thyristor Pulse
NOTICE
If a thyristor firing pulse is very high in ampli-
tude as compared to the other devices, suspect
Use the following oscilloscope settings when checking

armature thyristor pulses:
B. Sweep Rate = 2
7. If any of the thyristor firing pulses are found to be

improper, the pulses from the pulse amplifier cards
should be checked. These pulses can be monitored with
an oscilloscope connected to the output test points TP
(28342).

started, and brakes released, set the crowd controller to
the full RETRACT position. Check the pulses on the
pulse amplifier card in location 145. Check the crowd
pulses with the crowd controller in the full CROWD
position on the pulse amplifier card in location 141. The
pulse amplifier signal waveform should be similar to
those shown in Figure 6-35 and Figure 6-36.
Figure 6-33. Crowd/Propel Converters 9. Set the oscilloscope for the pulse amplifier output
6-29
12. To check the pulse generator card, simply monitor
the signals at test points TP 4, 5, 6, 8, 9 and 10 with an
in Figure 6-37, replace the pulse generator card.
Use the following oscilloscope settings for the pulse

generator output pulse:

transformer.
Figure 6-35. Pulse Amplifier Output Pulse

shown in Figure 6-36:
11. If the pulses are not similar to the photos in Figure

6-35 and Figure 6-36, either the amplifier board is
malfunctioning or the pulse generator is at fault.
DYNAMIC TESTING
Dynamic testing of the crowd motion control frame
oscilloscope.

signal as it reflects the current waveform fed to the DC
Figure 6-36. Pulse Amplifier Output Pulse (3 Pulses) To observe the current feedback signal, an oscilloscope
must be connected to TP 6 on the current regulator card
6-30
Set the oscilloscope to the following settings when
checking the armature current feedback (retract):
6. Sweep Rate = 2 milliseconds/division
7. If the waveforms are not correct, check the thyristors

and thyristor firing pulses.
THYRISTOR FIRING INFORMATION
If it is desired, the following procedure may be used to

identify a faulty thyristor while the motion is actually
being operated in ARMATURE TEST. However, to
confirm the findings, the test with the thyristor tester
Figure 6-38. Armature Current Feedback (Crowd) must always be done before replacing a suspect device.

(CCOM) TP 20 (28342).

oscilloscope. Also, use a 3 to 2 adapter on the
ARM TEST position.
2. Make sure all circuit breakers are in the ON position.
3. Start the machine and then press the crowd brake
RELEASE pushbutton.
4. While the operator slowly moves the controller in the
crowd direction, observe the waveform on the
oscillocscope. This waveform should be comparable to
Figure 6-39. Armature Current Feedback (Retract)
waveform is more important that the amplitude of the
current feedback signal. Use the following oscilloscope
settings: NOTICE
A. Amplitude = 1 volt While performing the following procedures,
there may be overcurrent shutdowns, fuse fail-
ures or circuit breaker trips. In this case, a
5. Repeat step 4, but move the controller to the thorough check of all devices using the thyris-
RETRACT position. The waveform should be similar to tor tester is in order.
the photo in Figure 6-38. Once again, the most
important thing to observe is if the waveform is Figure 6-21 provides the oscilloscope settings to be
symmetrical, i.e. the waveform is not unbalanced with used when checking thyristor firing. After setting the
small, missing, or oversized ‘humps’. oscilloscope controls, proceed as follows:
6-31
RETRACT BRIDGE CROWD BRIDGE
K04B3 #1 K04A4 #1
K04D3 #3 K04C4 #3
K04F3 #5 K04E4 #5
K04B4 #4 K04A3 #4
K04D4 #6 K04C3 #6
K04F4 #2 K04E3 #2
RETRACT CURRENT FEEDBACK WAVEFORM
K04B3 K04F4 K04D3 K04B4 K04F3 K04D4
1 2 3 4 5 6
RETRACT CURRENT FEEDBACK WAVEFORM
K04A4 K04E3 K04C4 K04A3 K04E4 K04C3

1 2 3 4 5 6
4 K04A3 K04A4 1
1 K04B3 K04B4 4
6 K04C3 K04C4 3
3 K04D3 K04D4 6
2 K04E3 K04E4 5
5 K04F3 K04F4 2
CROWD SCRs RETRACT SCRs
Figure 6-40. Crowd Converter
6-32
information the misfiring SCR should be quickly
FROM CURRENT TRANSFORMER
identified.
DYNAMIC PARAMETER CHECKS

•
The final steps in dynamic testing are to verify the
maximum values of voltage and current. These
• parameters can be checked using the following
• procedures.
• INST. Armature Current

O.L.
RELAY
1 3
•
! CAUTION
DANGER
The motor(s) should not be run at maxi-
mum stall current for more than 5 seconds
• • • at a time. Running with stall current for
CURRENT longer periods will cause localized heat-
ADJUSTING ing on the commutators.
RESISTOR
1. Set the test selector switch to the ARMATURE TEST
position.
2. Set the meter selector switch to the appropriate
AND METER MODULE motion to be checked, i.e. hoist, swing or crowd/propel.
3. Set the toggle switch in the up or ORANGE position
Figure 6-41. Current Adjusting Resistor if it is not there.
4. Place all circuit breakers in the closed (ON) position.
1. Connect channel number 1 of the scope to TP 6 of the
current regulator YXR104 on the applicable motion. 5. Press the STOP and then the START button on the
This is the current feedback signal. operator’s console.
6. Press the brake RELEASE pushbutton for the
2. Connect channel number 2 of the scope to TP 10 of motion being checked.
the firing pulse generator card YXU139B on the
applicable motion. This signal is the trigger source. 7. Move the appropriate controller to the full ON
position. Check the stall current value on the armature
The thyristor configurations and locations for the current meter. Consult the electrical data sheets for
different motions are shown in Figure 6-40. The the proper value of the stall current.
thyristor firing orders are also given, i.e. 1, 2, 3, 4, 5 and 8. Adjust the level of the current feedback in
6. accordance with the information provided in the
electrical data sheets.
As long as the scope is triggered properly, the first
‘hump’ of the current feedback signal will be the The adjustable resistor for changing the value of the
number 1 SCR in the firing order to turn on. With this current feedback which ultimately affects the amount

6-33
FROM DC BUS IN CONVERTER CABINET
Armature Voltage
VOLTAGE FEEDBACK. The voltage feedback signal is

directly proportional to the DC motor armature
voltages, and is therefore a useful signal for monitoring
1 2 3 4 a particular motion’s performance. The voltage
VOLTAGE feedback signal also goes to the meter panel for easy
ISOLATOR measurement of armature voltage during normal RUN
operation.
5 6 7 8
VOLTAGE FEEDBACK
ADJUSTING RESISTOR
The portion of the voltage feedback signal which is used
control may be monitored with an oscilloscope or chart
recorder to get a visual indication of the system’s
115 VAC
performance. This may be accomplished by connecting
• • • voltage regulator card and test point 20 (CCOM). The
polarity and amplitude of this DC signal will be directly
proportional to the motor armature voltage, and
therefore, an accurate indication of motor SPEED and
DIRECTION.
AND METER MODULE
In a properly operating system, a voltage feedback
Figure 6-42. Voltage Feedback Adjusting Resistor signal of +10V will indicate a full speed (+550V)
condition in the retract or reverse propel direction.
Similarly, -10V will indicate a full speed (-550V) in the
of motor current is shown in Figure 6-41. See the crowd or forward propel direction.
schematics for resistor identification number on page
12, line 37.
of motor voltage is shown in Figure 6-42. See the
schematics for resistor identification number.
6-34
113
117
121
125
129
137
141
145
-
Current Regulator
Voltage Regulator
Firing Pulse Amp.
Firing Pulse Amp.

Firing Pulse Gen.
Blocking Circuit
Blocking Amp
Adapter
Blank
Figure 6-43. Swing Armature Control Frame
SWING ARMATURE CONTROL Testing Components

FRAME
To test the control frame, proceed as follows:
This topic covers the static and dynamic testing of the

swing armature control frame components. These ! CAUTION
DANGER
circuits are located in the control cabinet as indicated Never move the test selector switch to an-
in Figure 6-43. Test each circuit using the following other test position without first pressing
procedures and test data. the STOP pushbutton in the operator’s
coop.

NOTICE position. This will allow only the control portions of the
Electrotorque system to be operational.
cal values. The actual voltages measured dur- 2. Place all circuit breakers in the closed or ON
ing testing may vary slightly. position.
3. Press the START pushbutton in the operator’s coop.

If at any time the voltage readings measured do not
correspond closely to the values given in the charts, 4. Press the swing brake RELEASE pushbutton in the
replace the circuit board under test and repeat the test operator’s coop.
procedure for that circuit board.
NOTICE
Figure 6-44 illustrates the typical control system in The boarding ladders must be raised so the lad-
block diagram form. der limit switch is in its closed position.
6-35
CONTROLLER
REFERENCE
6 0 AC
Vfb = - Ifb = +
- +
#141 To
TP18 - I. REF - TP6 + Vc
+ TP 19 TP2
+ V. REF + TP17 TP11 TP7 TP17 TP11 SCRS
-
“ON”
07A PULSE PULSE
SWING RIGHT INV “I” REF
- + 0V #145 To
TP8 TP15 TP16 TP2
SCRS
- TP6 5V “OFF”
TP16 - TP19 TP1
PULSE
Hoist or Propel Reverse

Vfb = Armature Voltage Feedback
NOTE: ON BLOCKING AMP.

5V = BLOCK
0V = DEBLOCKED
CONTROLLER
REFERENCE
6 0 AC
Vfb = + Ifb = +
- +
TP18 TP6
#141 To
- - V. REF - + I. REF + + Vc
SCRS
TP 19 TP2 TP17 TP11 TP7 TP17 TP11
+
“ON”
07A PULSE PULSE
SWING LEFT INV “I” REF
+ - 5V #145 To
TP8 TP15 TP16 TP2
SCRS
+ TP6 0V “OFF”
TP16 + TP19 TP1
PULSE
Figure 6-44. Swing Control Flow Chart
6-36
±15 VDC Regulator the meter selector switch should be set to the 60 volt
test position.
To test the ±15 VDC regulator supply, proceed as
follows: Circuit Board Tests
The ±15VDC supply is located behind the swing out
To test the remaining circuit boards in the swing
rack assembly.
armature control frame, proceed as follows:
1. Place the toggle switch on the meter panel to the
down or yellow position. 1. Refer to Table 6-22 and test the adapter, Table 6-23
to test the voltage regulator and Table 6-24 to test the
2. Set the meter selector switch to the + and then the - current regulator circuit boards.
15 volt hoist armature control position.
2. Press the swing brake SET pushbutton in the
3. Read the + and - voltages on the meter panel operator’s coop.
voltmeter. If the + and -15 volt DC supplies are not
correct or unobtainable, check the + and -24 volt 3. Press the swing brake RELEASE pushbutton in the
supplies. operator’s coop.
4. Place the toggle switch on the meter panel to the up 4. Refer to Table 6-25 through Table 6-28 and continue
or ORANGE position. with the remaining tests (the boarding ladder must be
raised).
5. Set the meter selector switch to the 30 volt test
position. If a lower voltage scale is needed, set the 5. Press the swing brake SET pushbutton in the
meter selector switch to the appropriate 3 volt or 12 operator’s coop. This completes the testing of the swing
volt position. When checking the pulse amplifier cards, armature control frame.
6-37
BOARD SET/REL POSITION TP TP
REL NEUTRAL 19 0 VDC

0 VDC
12 0 VDC
SWING ADAPTER
FULL RIGHT 19 +15

2 +10
11 +10
FULL LEFT 12 -10
19 -15
2 -10
11 +10
12 -10
Table 6-22. Swing Adapter

REL NEUTRAL 11 0 VDC

REGULATOR
VOLTAGE
FULL RIGHT 17 +10

11 -10
FULL LEFT 17 -10
11 +10

SET NEUTRAL 18 1 -VOLTAGE The value of voltage

at TP-18 is
REL NEUTRAL 18 1 +VOLTAGE
dependent on the
FULL RIGHT 7 -10 vintage of the
CURRENT REGULATOR
circuit board. If the

17 +8
polarity does not
FULL LEFT 7 +10 change, check
17 +8 external wiring to
PLC. See
Schematic.
TP-6 is the current
feedback signal test
point. TP-6 will have
a positive voltage
signal 0 to 10 V when
armature current is
present.
6-38
REL FULL RIGHT 6 -11
REL 8 -10
BLOCKING CIRCUIT
REL 9 0 VDC
REL 15 +9
REL 16 -5
REL FULL LEFT 6 +11
8 +10
9 -4.5
REL 15 -5
REL 16 +9

REL FULL RIGHT 16 +9 NOTE:

BLOCKING AMPLIFIER
REL 19 -5 TP-7 Should be

about +10 VDC.
REL 2 0 VDC If it is 0 VDC, sus-
REL 1 +5 pect a faulty di-
REL FULL LEGT 16 -5 verter module.
REL 19 +9
REL 2 -5
REL 1 0 VDC

REL NEUTRAL 15 +1.25

REL NEUTRAL 4 +3
FIRING PULSE
GENERATOR
REL NEUTRAL 5 +3
REL NEUTRAL 6 +3
REL NEUTRAL 8 +3
REL NEUTRAL 9 +3
REL NEUTRAL 10 +3
6-39
REL FULL RIGHT 3 +3 +3 Check card locat-
REL FULL RIGHT 2 +35 +35 ed in position
141.
REL FULL RIGHT 5 +3 +3
REL FULL RIGHT 19 +3 +3 The outputs may
REL FULL RIGHT 17 +35 +35 also be monitored
with an oscillo-
REL FULL RIGHT 11 0 VDC 0 VDC scope. See figure
REL FULL LEFT 2 +42 +42 Figure 6-47 for
proper waveform.
REL FULL LEFT 4 +42 +42

REL FULL RIGHT 2 +42 +42 Check card locat-
REL FULL RIGHT 4 +42 +42 ed in position
145.
REL FULL LEFT 4 +35 +35 The outputs may
REL FULL LEFT 7 +3 +3 also be monitored
with an oscillo-
REL FULL LEFT 6 +35 +35 scope. See figure
REL FULL LEFT 14 +3 +3 Figure 6-47 for
proper waveform.
REL FULL LEFT 11 0 VDC 0 VDC
6-40
QALB 214 Voltage Regulator
GAIN 20
TIME/GAIN .5
LIM 1 Max C.W.
LIM 2 Max C.W.
SIGN. ADJUSTMENT 0
YXN 110 Blocking Circuit

HYSTERESIS 3.5
PHASE LEAD 8
CURRENT LEVEL 3
YXR 104 Current Regulator

GAIN 3
**RESPONSE Max CW
YXU 139B-T12 Pulse Generator ADJUST TO .56 VOLTS 50Hz
Table 6-29. Settings For Board Switches And Potentiometers (4100)
SETTINGS FOR CIRCUIT BOARD To check the armature firing pulses, proceed as follows:
SWITCHES AND POTENTIOMETERS . 1. Set the test selector switch on the meter module to
the CONTROL TEST position.
Table 6-20 provides nominal settings for the
adjustment of swing motion control frame circuit board 2. Turn all circuit breakers to their ON position.
switches and potentiometers.
3. Start the machine, then press the swing brake
RELEASE pushbutton.
NOTICE
4. Move the swing controller to the full SWING RIGHT
Always use a small screwdriver to adjust po- position.
tentiometers and switches. The dial indicator is
a slip fit on the shaft and may turn without ac- 5. Check each of the swing right bridge thyristor firing
tually rotating the adjustment shaft. All set- pulses by connecting the probe of the oscilloscope to the
tings should be marked with a locking paint. white lead (gate) of the thyristor and the ground lead of
SWING CONVERTER Figure 6-46, when using the following oscilloscope
settings:
Figure 6-45 illustrates the locations of the swing
thyristors. A. Amplitude = 1 volt/division

Checking Thyristor Firing Pulses
6. Move the swing controller to the full SWING LEFT
The thyristor firing pulses should be checked whenever position and check each of the swing left bridge
a thyristor loss has been experienced or if the current thyristor firing pulses. This waveform should also be
feedback signal indicates a misfired device. similar to the waveform in Figure 6-46.
6-41
NOTICE
If a thyristor firing pulse is very high in ampli-
tude as compared to the other devices, suspect
7. If any of the thyristor firing pulses are found to be

improper, the pulses from the pulse amplifier cards
should be checked. These pulses can be monitored with
an oscilloscope connected to the output test points TP
(28342).

started, and brakes released, set the swing controller to
the full SWING LEFT position. Check the pulses on the
pulse amplifier card in location 145. Check the swing
right pulses with the swing controller in the full
SWING RIGHT position on the pulse amplifier card in
location 141. The pulse amplifier signal waveform
should be similar to those shown in Figure 6-47 and
Figure 6-48.
9. Set the oscilloscope for the pulse amplifier output

A. Amplitude= 20 volts/division
B. Sweep Rate= 2 milliseconds/division

shown in Figure 6-48:
A. Amplitude= 20 volts/division
Figure 6-45. Swing Converter Cabinet Figure 6-46. Armature Thyristor Pulse
6-42
To observe the current feedback signal, an oscilloscope

must be connected to TP 6 on the current regulator card
(CCOM) TP 20 (28342).

oscilloscope. Also, use a 3 to 2 adapter on the

ARM TEST position.
2. Make sure all circuit breakers are in their ON

Figure 6-47. Pulse Amplifier Output Pulse position.
3. Start the machine, and then press the swing brake

RELEASE pushbutton.
11. If the pulses are not similar to the photos in Figure 4. While the operator slowly moves the controller in the
6-47 and Figure 6-48, either the amplifier board is SWING RIGHT direction, observe the waveform on the
malfunctioning or the pulse generator is at fault. oscilloscope. This waveform should be comparable to
12. To check the pulse generator card, simply monitor waveform is more important that the amplitude of the
the signals at test points TP 4, 5, 6, 8, 9 and 10 with an current feedback signal.
in Figure 6-49, replace the pulse generator card. Use Use the following oscilloscope settings when checking
the following oscilloscope settings: the armature current feedback (swing right) waveform:
A. Amplitude = 5 volts/division A. Amplitude = 1 volt

transformer.
DYNAMIC TESTING
Dynamic testing of the swing motion control frame

oscilloscope.

signal as it reflects the current waveform fed to the DC Figure 6-48. Pulse Amplifier Pulse (3 Pulses)
6-43
A. Amplitude= 1 volt/division
6. If the waveforms are not correct, check the thyristors

and thyristor firing pulses.
If it is desired, the following procedure may be used to

identify a faulty thyristor while the motion is actually
being operated in ARMATURE TEST. However, to
confirm the findings, the test with the thyristor tester
must always be done before replacing a suspect device.
5. Repeat step 4, but move the controller to the SWING

LEFT direction. The waveform should be similar to the
photo in Figure 6-51. Once again, the most important
thing to observe is if the waveform is symmetrical, i.e.
the waveform is not unbalanced with small, missing, or
oversized ‘humps’.
Set the oscilloscope to the following settings when

checking the armature current feedback (swing left)
waveform:
Figure 6-51. Armature Current Feedback (Swing Left)
NOTICE
While performing the following procedures,
there may be overcurrent shutdowns, fuse fail-
ures or circuit breaker trips. In this case, a
thorough check of all devices using the thyris-
tor tester is in order.
THYRISTOR FIRING INFORMATION
Table 6-21 provides the oscilloscope settings to be used

when checking thyristor firing. After setting the
Figure 6-50. Armature Current Feedback (Swing Right) oscilloscope controls, proceed as follows:
6-44
1. Connect channel number 1 of the scope to TP 6 of the 7. Move the appropriate controller to the full ON
current regulator YXR104 on the applicable motion. position. Check the stall current value on the armature
This is the current feedback signal. current meter. Consult the electrical data sheets for
2. Connect channel number 2 of the scope to TP 10 of the proper value of the stall current.
the firing pulse generator card YXU139B on the
applicable motion. This signal is the trigger source. 8. Adjust the level of the current feedback in
accordance with the information provided in the
The thyristor configurations and locations for the electrical data sheets.
different motions are shown in Figure 6-52. The
thyristor firing orders are also given, i.e. 1, 2, 3, 4, 5 and
6. The adjustable resistor for changing the value of the
current feedback which ultimately affects the amount
As long as the scope is triggered properly, the first of motor current is shown in Figure 6-53. See the
‘hump’ of the current feedback signal will be the schematics for resistor identification number on page
number 1 SCR in the firing order to turn on. With this 10, line 37.
information the misfiring SCR should be quickly
identified.
Armature Voltage
DYNAMIC PARAMETER CHECKS
The final steps in dynamic testing are to verify the VOLTAGE FEEDBACK.The voltage feedback signal is
maximum values of voltage and current. These directly proportional to the DC motor armature
parameters can be checked using the following voltages, and is therefore a useful signal for monitoring
procedures. a particular motion’s performance. The voltage
feedback signal also goes to the meter panel for easy
measurement of armature voltage during normal RUN
Armature Current operation.
! CAUTION
DANGER The portion of the voltage feedback signal which is used
The motor(s) should not be run at maxi- control may be monitored with an oscilloscope or chart
mum stall current for more than 5 seconds recorder to get a visual indication of the system’s
at a time. Running with stall current for performance. This may be accomplished by connecting
longer periods will cause localized heat-
voltage regulator card and test point 20 (CCOM). The
ing on the commutators. polarity and amplitude of this DC signal will be directly
1. Set the test selector switch to the ARMATURE TEST proportional to the motor armature voltage, and
position. therefore, an accurate indication of motor SPEED and
DIRECTION.
2. Set the meter selector switch to the appropriate
motion to be checked, i.e. hoist, swing or crowd/propel.
In a properly operating system, a voltage feedback
3. Set the toggle switch in the up or ORANGE position signal will indicate a full speed (+600V) condition in the
if it is not there. swing left direction. Similarly, -10V will indicate a full
4. Place all circuit breakers in the closed (ON) position. speed (-600V) in the swing right direction.
5. Press the STOP and then the START button on the

operator’s console. The adjustable resistor for changing the value of the
6. Press the brake RELEASE pushbutton for the of motor voltage is shown in Figure 6-53. See the
motion being checked. schematics for resistor identification number.
6-45
RETRACT BRIDGE CROWD BRIDGE
K05A4 #1 K05B3 #1
K05C4 #3 K05D3 #3
K05E4 #5 K05F3 #5
K05A3 #4 K05B4 #4
K05C3 #6 K05D4 #6
K05E3 #2 K05F4 #2
SWING LEFT CURRENT FEEDBACK WAVEFORM
K05A4 K05E3 K05C4 K05A3 K05E4 K05C3
1 2 3 4 5 6
SWING RIGHT CURRENT FEEDBACK WAVEFORM
K05B3 K05F4 K05D3 K05B4 K05F3 K05D4

1 2 3 4 5 6
4 K05A3 K05A4 1
1 K05B3 K05B4 4
6 K05C3 K05C4 3
3 K05D3 K05D4 6
2 K05E3 K05E4 5
5 K05F3 K05F4 2
RIGHT SWING SCRs LEFT SWING SCRs
Figure 6-52. Swing Converter
6-46
FROM CURRENT TRANSFORMER FROM DC BUS IN CONVERTER CABINET
1 2 3 4
•
VOLTAGE
• ISOLATOR
5 6 7 8
• INST.
O.L. VOLTAGE FEEDBACK
RELAY ADJUSTING RESISTOR
1 3
•
115 VAC
• • •
• • •
CURRENT
ADJUSTING
RESISTOR
TO MOTION CONTROL FRAME CIRCUIT CARDS TO MOTION CONTROL FRAME CIRCUIT CARDS
AND METER MODULE AND METER MODULE
Figure 6-53. Current Adjusting Resistor Figure 6-54. Voltage Feedback Adjusting Resistor
6-47
SECTION 7
RPC SYSTEMS
GENERAL 60 Hz 50 Hz BANKS ON
STEP 4 STEP 4 1+2
This section provides the information necessary to troubleshoot STEP 5 STEP 5 1 + 2 + 1/2
the reactive power compensation system used in the
STEP 6 STEP 6 1+2+3
Electrotorque control system. A brief description of the
STEP 7 1 + 2 + 3 + 1/2 (60 Hz only)
functions and locations of the various components in the system
is followed by specific troubleshooting information for the
This compensation method limits reactive power to a fixed level
specific circuit boards used in the system.
of excursion. When the leading and lagging KVARs are
DESCRIPTION averaged, the result is unity power factor. This is automatic

reactive power compensation.
Electrotorque System Reactive Power
Compensation (RPC)
The Electrotorque system employs a Harnischfeger designed
reactive power compensation method that exactly and
RPC Cabinet
automatically accomplishes the objectives of power factor
correction.
Reactive power compensation consists of banks of stepped

The reactive power compensation components are housed in a
capacitors which are connected to the main transformer
secondaries. These banks of capacitor/reactors are switched in single cabinet. The cabinet is separated into three
and out of the circuit automatically under essentially zero compartments, one holding the thyristors for switching the
current conditions so that no transient currents are experienced. banks of capacitors on and off and the other two containing the
This system machine incorporates seven steps of RPC for 60 Hz reactors, capacitors, circuit breakers and indicators.
systems and six steps of RPC for 50 Hz systems. In the seven
step system, these steps are derived from three and one-half
banks of capacitor/reactor combinations. The 50 Hz system
uses three banks, two of which are half banks.
The locations of the RPC thyristors and diodes in various steps
The steps are brought on in the following sequence as the need are shown in Figure 7-1 through Figure 7-4.
for compensation increases.
60 Hz 50 Hz BANKS ON
STEP 1 STEP 1 1/2
STEP 2 STEP 2 1 The reactors, capacitors, breakers, and indicator assemblies are
STEP 3 STEP 3 1 + 1/2 shown in Figure 7-5.
7-1
Armature Transformer
Secondary 1
Step #1/2 Capacitors Step #2 Capacitors
Hoist and Swing

Armature Converters
Figure 7-1. RPC Systems
Figure 7-2. RPC Switching Cabinet (Inboard Side)
7-2
Armature Transformer
Secondary 2
Step #3 Capacitors Step #1 Capacitors
On 50 Hz machines, Step #3 is a 1/2 bank Hoist and Crowd

of compensation. On 60 Hz, it is full. Armature Converters
Figure 7-3. RPC Systems
Figure 7-4. RPC Switching Cabinet (Outboard Side)
7-3
CHECKING RPC POWER DIODES AND Testing Components
THYRISTORS
General
! WARNING
DANGER There are a number of general procedures that pertain to all
Before attempting to test the power devices used in circuit board tests in this subsection. Perform the following
the RPC systems, ALL circuit breakers must be in procedures prior to testing the circuit boards:
their OPEN positions. All RPC capacitors must
also be checked to make sure the stored energy has
been dissipated. A voltmeter can be used to check ! CAUTION
DANGER
for the presence of any voltage that may remain on
a capacitor. Never move the test selector switch from one test
position to another without first pressing the STOP
pushbutton on the operator’s console.
If a shorted diode or thyristor is suspected, the RPC indicator
panel that is mounted on the RPC cabinets should be observed 1. With the exception of the measuring amplifier board, test all
to determine the location of the suspect device. Directly below RPC circuit boards with the test selector switch set to the
each indicator panel is a decal explaining the RPC indicator CONTROL TEST position. This allows only the control
operation (see Figure 7-6). portions of the Electrotorque system to be operational.
To confirm a shorted RPC diode or thyristor, an ohmmeter can 2. Place all circuit breakers in the closed or ON position.
be used, measuring directly across the device. If the ohmmeter
reads zero ohms, either the diode or the thyristor that is 3. Press the STOP pushbutton in the operator’s coop.
connected in anti-parallel with it is shorted. Replace the
defective device using the information on proper mounting of 4. Press the START pushbutton in the operator’s coop.
power semi-conductors in Section 11 of this manual.
5. Check the ±15 VDC power supplies as described in the
following procedure and then proceed to testing the individual
In the event the RPC indicator panel does not indicate a suspect circuit boards.
defective device, and no shorted devices can be found with an
ohmmeter, all of the devices in the problem step should be
tested with the thyristor tester. See Section 10 for information Testing the ±15 Volt Power Supplies
on proper procedures. These tests are necessary to find an
intermittent device that may be breaking down when higher Test the ±15 VDC power supplies prior to testing the individual
voltages are applied. circuit boards as follows:
1. Place the toggle switch on the meter panel to the down or

Testing the RPC Control Frame YELLOW position.
2. Set the meter selector switch to the + and then the -15 volt
General REACTIVE POWER COMPENSATOR control position.
This topic covers the static testing of the RPC control frame 3. Read the + and - voltages on the meter panel voltmeter.
circuit boards. The RPC control frame assembly consists of the
following circuit boards. 4. For the remainder of the tests, place the toggle switch on the
meter panel to the up or ORANGE position. Set the meter
1. ±15 Volt DC supply. selector switch to the appropriate 3 volt, 12 volt 30 volt or 60
volt position.
2. Measuring amplifier.
3. Level detectors. Measuring Amplifier

4. Firing pulse reference unit. To test the measuring amplifier, proceed as follows:
Figure 7-7 shows the orientation of the RPC control frame 1. With the test selector in the CONTROL TEST position, press
circuit boards as well as their location numbers. the START pushbutton on the operator’s console.
7-4
Figure 7-5. RPC Cabinet (Inboard Side)
2. Measure the amplifier’s output signal at test point 13. This 4. Press the START pushbutton on the operator’s console.
signal should now measure 0 VDC.
5. With the meter set to the 12 volt range, monitor the
amplifier’s output at test point 13.
! CAUTION
DANGER
Dynamic testing of the measuring amplifier cannot
be completed until it has been determined that the ! CAUTION
DANGER
rest of the RPC system is functioning properly. If it
has been determined that the entire RPC system is Do not stall the hoist armature for a period longer
functioning properly and a dynamic test of the than five (5) seconds.
measuring amplifier is desired; press the STOP
pushbutton on the operator’s console and continue 6. Press the hoist brake RELEASE pushbutton on the operator’s
with Step 3. Otherwise, skip to the Level Detector console and stall the hoist motion-"full hoist".
Tests.
3. Place the test selector switch in the ARMATURE TEST 7. During full hoist stall, the amplifier’s output at test point 13
position. should measure 4.4 VDC ±.5.
7-5
Interface Circuit
To test the interface circuit board, proceed as follows:
1. Check to see that +15VDC is present at TP-4 of this card.
2. With the jumpers between TP 17 and TP 1 on both level
detectors still intact-measure for +15V at TP-1, TP-2, TP-8 and
TP-9 on the interface card.
3. Remove the jumper between TP-17 and TP-1 on the level
detector cards. The voltage at TP-1, TP-2, TP-8, and TP-9
should now read 0V.
4. Reinstall the measuring amplifier circuit board.
Checking The RPC Firing Module

Figure 7-6. RPC Indication
General
If the output voltages are not as specified, check the input The RPC firing modules generate the required thyristor firing
voltages at TP 11 with a digital multimeter. With the hoist pulses for the RPC thyristors. If it is suspected that a RPC
motion stalled these voltages should be .44 VDC ±.05. module is malfunctioning, the following tests may be
performed to locate the suspect unit.
If these voltages are not correct, check both 115 VAC supplies
to the KVAR transducer terminals 3, 4, 5, and 6; check both
summing transformers, and/or replace the KVAR transducer. Testing The RPC Firing Module
See schematics, pages 4, 5, and 30. 1. Start machine in the ARMATURE TEST mode.
8. Press the hoist BRAKE SET pushbutton on the operator’s
2. Stall the hoist and crowd motions while observing the RPC
console.
indicator to determine which step and phase the suspect unit is
in.
Level Detectors 3. Shut the machine down.
To test the level detectors, proceed as follows: 4. Using an appropriate meter, check for 120 VAC on the
terminals marked 120 VAC on the module.
NOTICE 5. Remove the measuring amplifier circuit board. Connect a
jumper wire from test point TP 1 on the level detector card to
The excavator need not be started to test this board. TP 17 on the level detector card. Do this on both level detector
1. Remove the measuring amplifier circuit board from the RPC cards.
control frame.
121 125 129 133
2. Using a jumper wire, connect test point 17 (level detector
input) to test point 20 (0 volts).
MEASURING
DETECTOR
DETECTOR
INTERFACE
AMPLIFIER
3. Measure the detector’s outputs at test points TP 3, TP 5, TP

CIRCUIT
LEVEL
LEVEL
8, TP 9, TP 11, and TP 13. All outputs should measure 0 VDC.

4. Reconnect the jumper wire to connect test point 17 (level
detector input) to test point 1 (+15 VDC).
5. Measure the detector’s outputs at test points TP 3, TP 5, TP
8, TP 9, TP 11 and TP 13. All outputs should now measure +15
VDC.
Figure 7-7. RPC Control Frame Components
6. Repeat this test for the other level detector card.
7-6
6. Monitor the 5 VOLT CONTROL LED on each RPC module. characteristics of the thyristors with and without current being
This LED should now be illuminated. As an additional check, carried.
measure approximately 5 VDC on the + or - terminals marked
"5 VDC Control". 13. Check to see that the pulse width is about 400 microseconds
wide.
If the 5 VDC is not present, check for loose cannon connectors
on the RPC control frame. Remove the jumpers and reinstall the The oscilloscope settings for the waveform are as follows:
measuring amplifier. A. Amplitude = 1 volt/division
7. The following steps outline how to test for the proper firing B. Sweep Rate = .1 milliseconds/division
pulse from the RPC firing module.
14. When the machine is started the AC ANODE LED should
8. Make sure the system is in the ARMTEST mode of operation. be illuminated. When the motion(s) are stalled the 5 VOLT
9. Connect an oscilloscope to the gate (G) and cathode (K) CONTROL LED should be illuminated as well as the GATE
terminals of the RPC firing module. PULSE LED.
Disregard the SCR FIRED LED.

! WARNING
DANGER
Be sure the oscilloscope is isolated from machinery
ground. Also be sure to use an isolation transform-
er to power the scope.
Do not touch the frame of the oscilloscope as it will be at a high

potential(approximately 600 VRMS).
10. Start the machine. Check to see that the AC ANODE voltage
LED is illuminated. If not, shut the machine down and check the
96K ohm resistor network associated with the module. Replace
it if it does not read 96K ohms. See schematics page 78.
11. While stalling the hoist and/or crowd motors, observe the
waveform on the oscilloscope. It should be similar to the photo
in Figure 7-8.
B. Sweep Rate = .2 milliseconds/division
12. Pay close attention to the leading edge of the waveform in
Figure 7-8. It must be a sharp fast rising waveform. The trailing Figure 7-8. RPC Firing Pulse
edge may not look exactly like the photo due to different
7-7
SECTION 8
DIVERTER SYSTEMS
DESCRIPTION 5. After the capacitor voltage is dissipated, the power in the

motor is allowed to dissipate through the grid resistor GR-1,
diode D1 and, of course, thyristor T-1.
The diverter circuit is a completely static armature current fault
limiting circuit for use with converter systems. Motor armature
6. If a fault occurred while operating in the other direction, the
current is monitored continuously and should it ever exceed a
active devices would be T-2, C-2, D-2 and GR-1 again.
preset level for any reason, the diverter control circuit initiates
the shutdown sequence. During a shutdown, the SCR bridge is 7. The contacts labeled CCR (when closed as shown) will de-
force commutated off while the motor current is diverted to a energize the capacitor C-1 and C-2 when the machine is
resistor. Hence, the name diverter circuit. The resistor dissipates shutdown in the normal manner. When the machine is in
the stored energy of the motor until the motion brakes can set. operation, these contacts will be open, allowing the capacitor C-
1 and C-2 to be charged up.
The primary purpose of the diverter circuit is to prevent motor
flashover due to excessive currents such as can occur during
power loss while regenerating. In addition to protecting the STATIC TESTS
motor, loss of thyristors and fuses due to high DC current faults
should be almost eliminated. Being a static device, the diverter
The static tests that should be done when troubleshooting the
circuit can react to and then reduce fault level armature currents
diverter systems are as follows:
to acceptable levels within a few milliseconds. This is
considerably faster than is possible with fuses or electro- 1. Testing the Diverter Module
mechanical devices.
2. Testing the Diverter Firing Circuit Assembly
A brief description of operation of the diverter system is as
follows (see Figure 8-1). 3. Testing the Diverter Diodes and Thyristors
1. The diverter systems protect the motors in either direction. 4. Testing the Diverter Capacitors
For simplicity, the explanation will assume power from (+) to (-
). 5. Testing the Diverter Charging Circuits
2. When an overcurrent is detected by the current sensing 6. General Checks

device, the first thing to occur is that the gating pulses to the
bridge thyristor are removed. By doing this, the thyristors are
not allowed to be turned on again. TESTING THE DIVERTER MODULE
3. At nearly the same time, thyristor T-1 receives a positive
gating signal from the diverter firing circuit assembly and General
control module.
4. Capacitor C-1 was previously charged to a value higher than In order to properly test the diverter module, it must be removed
the peak of the AC line to the converter by a separate charging from the machine and bench tested. The equipment required for
system. Now that the thyristor T-1 is on, the energy from C-1 bench testing the diverter module is as follows:
discharges to force commutate any thyristors that may be on to
their off state. • Two variable 24 volt DC power supplies
8-1
BRIDGE RESISTORS
- 5K
+
CCR CONTACTS
5K
T-1
D-1
GRID GR-1
RESISTOR
D-2
T-2
C2
5K
FROM CHARGING 5K CCR CONTACTS

TRANSFORMER
AND RECTIFIER
TO DIVERTER CURRENT
MODULE SENSING
DEVICE
DC
MOTOR
Figure 8-1. Typical Diverter Circuit
8-2
• One SPST toggle switch 2. Connect the negative probe from the digital meter to TP 2.
• One SPDT toggle switch (center off) Connect the positive probe into the number 2 socket of the
current sensor jack on top of the module. The meter must read
• Two 3.9 K ohm 1/2 watt resistors +14.5 to +15.5 VDC.
• Two 10 K ohm 1/2 watt resistors 3. Connect the positive probe into the number 5 socket of the
current sensor jack. The meter must read -14.5 to -15.5 VDC.
• Two 20 K ohm 1/2 watt resistors
4. Close switch S-1. The READY light should now be
illuminated.
• One digital voltmeter
Set up the module for testing in accordance with the diagram Checking the Trip Reference Circuitry
shown in Figure 8-2. Make sure S-1 and S-2 are in their open
positions.
To check the trip reference circuitry, proceed as follows:
Checking the ±15 VDC Power Supply 1. Connect the meter probes into TP 1(+) and TP 2(-). Rotate the
TRIP ADJ pot. to its full C.C.W. position. The meter should
To check the ±15 VDC Power Supply, proceed as follows: read +2.20 VDC to +2.5 VDC.
1. Turn on the 24 VDC power supply; none of the lights on the 2. Rotate the TRIP ADJ pot. to the full C.W. position. The meter
module should be illuminated. should read +6.5 VDC to +8 VDC.
3. Adjust the TRIP ADJ pot. so the meter reads +5.0 VDC, ±.05
NOTICE VDC.
The READY light may be faintly lit, but this can be ig- 4. Connect a DC power supply to TB1-4(+) and
nored. TB1-5(-). Adjust the power supply output for +10 VDC.
24 VDC
+ -
S2
S1 POS 2 POS 1
3.9 ¾ 3.9 ¾
TB1 2 3 4 5 6 7 8 9 10
CURRENT
TRIP ADJ.
TP1
FWD REV.
TRIP READY TRIP TP2
TP3
TB1 2 3 4 5 6 7 8 9 10
10 ¾
20 ¾ 20 ¾ 10 ¾
Figure 8-2. Diverter Module Testing Diagram
8-3
The digital meter should now read +3.75 VDC to +3.90 VDC. Checking the C.T. Current Trip Circuitry
5. Reverse the power supply leads connected to TB1-4 and
TB1-5. To check the C.T. current trip circuitry, proceed as follows:
1. Switch the S-2 toggle switch to position 1 (see Figure 8-2).

The meter must again read +3.75 to 3.90 VDC.
2. Connect the DC power supply leads to TB1 -6(+) and TB1 -
6. Disconnect the DC power supply leads. The meter should
7(-).
read +5.0 VDC ±.05 VDC.
Slowly increase the output from the power supply from zero
Checking the Current Trip Circuitry volts to a point where the FWD trip light is illuminated. The
power supply voltage should be between +14.5 VDC and +15.5
To check the current trip circuitry, proceed as follows: VDC when the FWD light turns on.
1. Connect the DC power supply to test point TP 3(+) and TP 3. Reduce power supply to zero volts. The FWD trip light must
2(-). Slowly increase the power supply voltage from zero volts remain on. Open S-1 toggle switch. Only the READY light must
to +10 VDC. turn off.
4. Close S-1 toggle switch. The READY light must turn back on
The FWD trip light must turn on when the power supply voltage
and the FWD trip light should turn off.
is between +8.20 VDC and +8.45 VDC.
5. Switch S-2 to position 2. Repeat steps 2, 3, and 4. The REV
Reduce the power supply voltage to zero volts. The FWD trip trip light must now turn on and off instead of the FWD trip light.
light should remain on.
2. Connect the digital voltmeter leads to TB2-1(+) and TB2-2(- Checking the Timer and Remaining Cir-
). The meter must read less than +1.0 VDC.
cuits
3. Open S-1 toggle switch. Only the READY light must turn off.
To check the timer and remaining circuits, proceed as follows:
4. Close S-1 toggle switch. The READY light must turn on.
1. Connect the digital voltmeter leads to TB2 -7(+) and TB2 -
The FWD trip light should turn off. The digital voltmeter should 6(-). The meter should read +24 VDC.
now read +24 VDC.
5. Reverse the DC power supply connected to TP 3 and TP 2 so NOTICE

TP 3 = (-) and TP 2 = (+). Slowly increase the output voltage
from zero to +10 VDC. The REVERSE trip light should turn on If the digital voltmeter reads zero, it is necessary to
when the power supply voltage is between +8.20 VDC and wait about one minute after the circuit last tripped,
+8.45 VDC. then the meter should read +24 VDC.
Reduce the power supply voltage to zero. The REVERSE trip 2. Increase the DC power supply voltage (still connected to TB1
light must remain on. -6(+) and TB1 -7(-)) until the circuit trips. The digital voltmeter
should read zero volts. Reduce power supply to zero volts. After
6. Connect the digital voltmeter leads to TB2 -3(+) and TB2 - about one minute, the digital voltmeter should read +24 VDC.
2(-). The meter must read less than +1.0 VDC.
3. During the time the digital meter is reading zero volts,
7. Open S-1 toggle switch. Only the READY light must turn off. connect the digital to TB2 -9(+) and TB2 -10(-). The meter
should read less than +2.5 VDC.
8. Close S-1 toggle switch. The READY light must turn on
again. 4. After about the one minute period, the digital should read
+17.5 VDC to 22.5 VDC.
The REV trip should turn off. The digital voltmeter should now
read +24 VDC. This completes the testing of the diverter module.
8-4
Figure 8-3. Diverter Firing Circuit Assembly
TESTING THE DIVERTER FIRING the diverter thyristor firing pulse (gate and cathode) are made
via "fast on" connectors mounted on the circuit board.
CIRCUIT ASSEMBLY
The purpose of the firing circuit assembly is to provide the Use the following procedure to test the diverter firing circuit
proper thyristor gating signal to turn on the diverter thyristor(s). assembly:
The diverter firing circuit assembly receives a command signal 1. Equipment required for this test:
from the diverter module on TB1-1 (CCOM) and TB1-2. Power
needed to operate the firing circuit assembly is brought in on
TB1-3 (CCOM) and TB1-4 (+24 VDC). The connections for • Chart recorder, Model 220 (Part No. 89Z471)
8-5
Figure 8-4. Diverter Firing Circuit Pulse
• Test leads 6. Connect the chart recorder to the diverter firing circuit
assembly as shown in Figure 8-3.
• Voltmeter
7. Check for +24 VDC on the diverter firing circuit assembly
2. Set the test selector switch to the CONTROL TEST position. TB1-4 (+24V) and TB1-3 (CCOM).
Make sure the control and relay supply circuit breakers are ON.
8. Set the sensitivity control on the recorder to 50 millivolts.
3. For proper use of the chart recorder, Refer to the PROPER This means that each small division on the chart paper is equal
OPERATION OF THE BRUSH RECORDER topic in Section to 50 millivolts.
10.
9. Set the chart recorder to 125mm speed.
4. Set up a chart recorder to monitor two separate signals
without a common reference. This can be done by opening the
links between the input terminals "2" and "G" on the recorder 10. Using a test lead, jumper terminals TB1-1 to TB1-2 on the
(see Section 10). firing circuit assembly.
5. Make sure the diverter thyristors are not defective. Thyristor 11. The signals from the diverter firing circuit assembly are very
gate and cathode connections must be maintained to provide a fast and only remain on for a short period of time. A proper
load for the firing circuit. pulse taken with a chart recorder is shown in Figure 8-4.
8-6
TESTING DIVERTER CAPACITORS
GRID RESISTOR
The diverter capacitor stores energy at approximately 1300
volts DC. This energy is used to force commutate the bridge
thyristors to their OFF positions when the diverter system
33K
33K
operates.
To test the diverter capacitors, proceed as follows:
DPR
! WARNING
DANGER
Before proceeding to test the diverter capacitors,
make sure the machine is shut down and all circuit
breakers are in their OPEN positions.
TO SHUTDOWN CIRCUITRY 1. Make sure the energy in the capacitor has been dissipated
before attempting to check the capacitor. This can be done by
making sure the capacitor charging relay (CCR) is de-
Figure 8-5. Secondary Shutdown Circuit energized, its NC contacts will provide a path to dissipate the
energy through the 5 K ohm resistor (see Figure 8-1).
12. If a pulse as shown in Figure 8-4 is not present, replace the
diverter firing circuit. 2. Disconnect all leads/cables to the capacitor.
TESTING DIVERTER THYRISTORS 3. The diverter capacitors can be checked by using an

ohmmeter. Readings should be taken from each capacitor
AND DIODES terminal to ground. These readings should read infinite ohms.
4. Connect the ohmmeter across the capacitor terminals. The

! WARNING
DANGER ohmmeter should be set to the RX10 or RX100 scale. A meter
Before attempting to check the conditions of the di- deflection toward zero ohms should occur. As the capacitor
verter diodes or thyristors, the machine must be charges up to the ohmmeter potential, the meter should read
shut down and all circuit breakers set to their open infinite ohms. Reverse the ohmmeter leads. The same meter
positions. action should occur. If the meter stays at zero ohms, the
capacitor is shorted and must be replaced.
A quick check of the diverter diodes or thyristors may be done
with an ohmmeter. The ohmmeter will read zero ohms if the
device is shorted.
TESTING THE DIVERTER CHARGING
CIRCUITS
The diodes or thyristors may be tested further using the thyristor
tester (Part No. 89Z511D1). Information regarding the The diverter charging circuit is used to pre-charge the diverter
parameters and procedures for testing the devices can be found capacitors. At full charge, the capacitor will have a potential of
in Section 11 of this manual. Information on the operation of the about 1300 volts DC.
thyristor tester can be found in Section 10 of this manual.
The charging circuit consists of a transformer and rectifiers. The

If the diodes or thyristors are to be tested using the thyristor
primary voltage on the transformer is 240 VAC, the secondary
tester they must be removed from the heat sink and inserted in
is 960 VAC.
the thyristor clamp supplied with the tester. If the devices are to
be tested in the machine heat sink, the cables on one side must
be opened to eliminate false readings on the tester due to dv/dt If the capacitor cannot be charged up to its full potential, check
circuits, etc. for:
8-7
1. A shorted power diode. CROWD = (+)
SWING RIGHT = (+)
2. A defective bridge rectifier.
3. A defective charging transformer. The meter should now read less than .1 VDC.
4. An inoperative diverter charging relay.
3. Connect a jumper from TB2-9 to TB2-10 on the diverter
5. An open 5 K ohm resistor. control module. The meter should now read +5 VDC.
6. DC side of bridge rectifier is connected incorrectly.
4. Return the controller to neutral.
7. An improper primary wiring on charging transformer.
5. Remove the jumper.
GENERAL CHECKS
6. Press the STOP pushbutton.
The diverter systems incorporate a secondary shutdown circuit.
The purpose of this circuit is to shut the machine down in the
event a diverter thyristor becomes shorted. CHECKING THE CURRENT SENSOR OUTPUT. To check
the current sensor output, proceed as follows:
This circuit consists of 2 resistors, 2 zener diodes and a relay. A
typical circuit can be seen in Figure 8-5. 1. Connect a meter to test points TP 2(-) and TP 3(+) on the
diverter module.
The fault panel light OVERCURRRENT FAULT will be
illuminated.
2. Set the test selector switch to the ARMATURE TEST
DYNAMIC TESTING DIVERTER SYSTEMS. To dynamic position.
test the diverter systems, use the following procedure:
3. Press the START pushbutton. Press the proper motion brake
1. Check that the control monitor circuit board is removed.
RELEASE pushbutton.
2. Check that the relay and control supply circuit breakers are
closed. 4. Set the controller to the FULL (+) reference position.
3. Set the test selector switch to the CONTROL TEST position.
4. Connect a voltmeter to TB1-1(+) and TB1-2(-) on the diverter
module. The voltmeter should read +24 VDC.
NOTICE
5. Press the START pushbutton. For the c/p motion, the system must be in the PROPEL
mode.
6. Check that the READY light on the diverter module is
illuminated. The meter connected to TP 2 and TP 3 should now read
per the following formula:
CHECKING THE BLOCKING SYSTEMS. To check the
ARMATURE CURRENT STALL
blocking systems, proceed as follows: VOLTS = ±.5VDC
300
1. Connect the meter module panel meter to the blocking
1550 AMPS
amplifier card YXN 109: T2 on the proper motion frame. The EXAMPLE: = 5.2VDC ±.5VDC
300
meter should read approximately +5 VDC.
Press motion brake release button. 5. Press the STOP pushbutton. Remove the meter from the
diverter module
2. Set the controller to the FULL POSITIVE REFERENCE
position.
CHECKING THE CAPACITOR CIRCUITS.To check the
HOIST = (+) capacitor circuits, proceed as follows:
8-8
1. Connect a meter across one of the diverter capacitors on the A. Connect a voltmeter to the diverter capacitor terminals.
motion under test. Repeat steps 5 and 6; the capacitor voltage should drop
instantly to zero volts when the machine shuts down.
! WARNING
DANGER
Use extreme caution when making voltage mea- B. When checking the other capacitors in the crowd and swing
surements in this section of the test procedure. motions, the controllers must be moved to obtain a negative
reference, i.e.:
2. Press the START pushbutton.
3. Measure the voltage across the capacitor terminals. This SWING LEFT = (-)
voltage should be approximately 1300 VDC. It is advisable to RETRACT = (-) (Propel Reverse)
use a digital multimeter. If one is not available, check machine
schematics for polarities.
4. Repeat the test in step 3 for the other capacitor in the circuit.
6. Check that the capacitor voltage decays to less than 50 volts ADJUSTING THE CURRENT TRIP FOR NORMAL
within 30 seconds. OPERATION
CHECKING THE OPERATION OF THE DIVERTER

CONTROL SYSTEM. To check the operation of the diverter
1. Connect the meter to test point TP 1(+) and TP 2(-) on the
control system, proceed as follows:
diverter control module under test. Set the trip adjustment pot
1. Connect a meter to test point TP 1(+) and TP 2(-) on the fully clockwise.
diverter control module under test.
2. Adjust the current trip adjustment potentiometer so the meter
reads +1.75 VDC. 2. While stalling the appropriate motion, turn the current trip
adjustment pot down until the machine shuts down. Note the
3. Make sure the test selector switch is set to the ARMATURE meter reading at the point of shutdown.
TEST position.
4. Reconnect the meter to test point TP 3(+) and TP 2(-) on the
diverter control module under test. 3. Multiply the meter reading by 1.4 and adjust the pot to that
reading on the voltmeter.
5. Press the START pushbutton. If testing the c/p diverter,
transfer to PROPEL.
6. Slowly increase the controller to the positive position, i.e.: 4. Press the STOP pushbutton.
HOIST = (+)
CROWD = (+) (Propel Forward)
5. If nuisance tripping occurs during normal operation, increase
SWING RIGHT= (+)
the current trip setting by increments of 0.1V until nuisance
7. Check that the machine shuts down when the meter reads 2.9 tripping does not occur.
VDC.
8. To check that the diverter thyristors actually fired, the
following should be done: This completes the dynamic testing of the diverter system.
8-9
SECTION 9
AUXILIARY SYSTEMS
AUXILIARY CABINET thermal overload (TOL) condition. The Programmable Message

Display will indicate an auxiliary motor fault screen.
The auxiliary cabinet is located in the right front area of the
machinery house. Equipment for controlling and protecting the Directly below the indicator lamps is a ground fault test panel
machine’s auxiliary systems is contained in this cabinet. used to simulate ground faults in the main, field and auxiliary
circuits during P.M. checks. See Figure 9-2. A 460V meter is
A fault indicator panel is located on the front panel of the mounted below the grid fault test pushbutton.
auxiliary cabinet to show the operational status of the auxiliary
pump motors and blowers. A PUSH TO TEST type of fault The auxiliary cabinet is laid out in a manner that corresponds to
lamp is used on some machines. When pushed, this lamp will the component identification as listed on the machine
illuminate to indicate that the specified component is schematics. As an example, the "Rear Swing Blower Motor
functioning normally. If the PUSH TO TEST indicators are not Starter" is identified as A02A5 on on page 21 of the machine
used, a single pushbutton is incorporated to check all of the schematics. As can be seen in Figure 9-1, the motor starter is
components simultaneously. When pressed, all lamps will located in the "A02" panel, Row "A", fifth item from the left.
illuminate. During normal operation of the machine, all of the
lamps should be illuminated. When the machine is shut down TROUBLESHOOTING
the lamps will not be lit. alarm will sound in the operator’s coop.
This indicates that in 30 seconds the machine will automatically Use Tables 9-1 through 9-17 as a guide when encountering
shut down. Prior to the actual shutdown, the operator should auxiliary circuit problems.
safely park the machine.
Because, as stated, the indicator lamps will not be illuminated GROUND FAULT TESTS
when the machine is shut down, the electrician must observe the
indicator panel during the 30 second period to determine which The auxiliary cabinet also contains the ground fault test and
auxiliary motor is inoperative due to a tripped breaker or a detection circuitry.
9-1
SWING LUBE PUMP SWING LUBE PUMP
Starter #1 (2300XPB Only) Starter #2 (2300XPB Only)
Figure 9-1. Auxiliary Cabinet
9-2
FRONT HOIST REAR HOIST FRONT SWING REAR SWING
BLOWER BLOWER BLOWER BLOWER
PROPEL #1 PROPEL #2 CROWD CONVERTER CONVERTER RPC SWITCH

BLOWER BLOWER BLOWER #1 BLOWER #2 BLOWER BLOWER
MACHINERY MACHINERY
HOUSE HOUSE HOIST LUBE DIPPER TRIP DIPPER TRIP
BLOWER BLOWER PUMP MOTOR #1 MOTOR #2
MAIN TRANSFORMER AUX. TRANSFORMER FIELD TRANSFORMER

GND. FAULT TEST GND. FAULT TEST GND. FAULT TEST
Figure 9-2. Auxiliary Cabinet Fault Indicators
9-3

MACHINERY MACHINERY
TROUBLE/SHUTDOWN MODE POSSIBLE CAUSE SOLUTIONS

Front hoist blower motor lamp is not il- Thermal overload trip caused by:
luminated.
1. Improperly sized elements. Install proper elements
A 30 second delayed shutdown. 2. Binding fan/motor. Repair accordingly.
3. Defective motor. Replace motor.
See schematics page 20. 4. Single phasing of motor. Check for an open TOL element, and
for inoperative or welded contacts on
FHBC contactor.
Tripped circuit breaker. Reset breaker.
Defective ASR1 relay. Replace ASR1 relay.
Defective FHBC coil in motor starter. Replace motor starter.
Defective indicator lamp. Replace bulb or lamp assembly
Table 9-1. Front Hoist Blower Motor Fault
9-4

MACHINERY MACHINERY

Rear hoist blower motor lamp is not il- Thermal overload trip caused by:
luminated.
RHBC contactor.
Defective RHBC coil in motor starter. Replace motor starter.
Table 9-2. Rear Hoist Blower Motor Fault
9-5

MACHINERY MACHINERY

Front swing blower motor lamp is not il- Thermal overload trip caused by:
luminated.
FSC contactor.
Defective FSC coil in motor starter. Replace motor starter.
Table 9-3. Front Swing Blower Motor Fault
9-6

MACHINERY MACHINERY

Rear swing blower motor lamp is not Thermal overload trip caused by:
illuminated.
RSC contactor.
Defective RSC coil in motor starter. Replace motor starter.
Table 9-4. Rear Swing Blower Motor Fault
9-7

MACHINERY MACHINERY

Propel No. 1 blower motor lamp is not Thermal overload trip caused by:
illuminated.
NOTE: 4. Single phasing of motor. Check for an open TOL element, and
Blower motor and light are only opera- for inoperative or welded contacts on
tional in the propel mode. PBC1 contactor.
Defective PBC1 coil in motor starter. Replace motor starter.
Table 9-5. Propel No. 1 Blower Motor Fault
9-8

MACHINERY MACHINERY

Propel No. 2 blower motor lamp is not Thermal overload trip caused by:
illuminated.
tional in the propel mode. PBC2 contactor.
Defective PBC2 coil in motor starter. Replace motor starter.
Table 9-6. Propel No. 2 Blower Motor Fault
9-9

MACHINERY MACHINERY

Crowd blower motor lamp is not illumi- Thermal overload trip caused by:
nated.
tional in the propel mode. CMBC contactor.
Defective CMBC coil in motor starter. Replace motor starter.
Table 9-7. Crowd Blower Motor Fault
9-10

MACHINERY MACHINERY

Converter No. 1 blower motor lamp is Thermal overload trip caused by:
not illuminated.
MTCR contacts are in parallel with for inoperative or welded contacts on
ASR2 contacts so the blowers will run CBC1 contactor.
when the test selector switch is in the Tripped circuit breaker. Reset breaker.
ARMATURE TEST position.
See schematics page 22. Defective CBC1 coil in motor starter. Replace motor starter.
Table 9-8. Converter No. 1 Blower Motor Fault
9-11

MACHINERY MACHINERY

Converter No. 2 blower motor lamp is Thermal overload trip caused by:
not illuminated.
ASR2 contacts so the blowers will run CBC2 contactor.
See schematics page 22. Defective CBC2 coil in motor starter. Replace motor starter.
Table 9-9. Converter No. 1 Blower Motor Fault
9-12

MACHINERY MACHINERY

RPC Cabinet blower motor lamp is not Thermal overload trip caused by:
illuminated.
ASR2 contacts so the blowers will run RBC contactor.
See schematics page 22. Defective RBC coil in motor starter. Replace motor starter.
Table 9-10. RPC Switch Blower Motor Fault
9-13

MACHINERY MACHINERY

Machinery Cab blower motor lamp is Thermal overload trip caused by:
not illuminated.
2. Binding fan/motor. Repair accordingly.
See schematics page 22. 3. Defective motor. Replace motor.
4. Single phasing of motor. Check for an open TOL element, and
MHBC contactor.
Defective MHBC-1 coil in motor starter. Replace motor starter.
Table 9-11. Machinery House Blower Motor Fault
9-14

MACHINERY MACHINERY

Machinery Cab blower motor lamp is Thermal overload trip caused by:
not illuminated.
2. Binding fan/motor. Repair accordingly.
See schematics page 22. 3. Defective motor. Replace motor.
MHBC contactor.
Defective MHBC-2 coil in motor starter. Replace motor starter.
Table 9-12. Machinery Cab Blower Motor Fault
9-15

MACHINERY MACHINERY
HOUSE HOUSE SWING LUBE HOIST LUBE DIPPER TRIP SWING LUBE
BLOWER BLOWER PUMP #1 PUMP MOTOR #1 PUMP #2
2300XPB ONLY

Swing Lube Pump motor lamp is not il- Thermal overload trip caused by:
luminated.
SLPC contactor.
Defective SLPC-1 coil in motor starter. Replace motor starter.
Table 9-13. Swing Lube Pump Front Motor Fault (2300XPA Only)
9-16

MACHINERY MACHINERY

Hoist Lube Pump motor lamp is not illu- Thermal overload trip caused by:
minated.
HLPC contactor.
Defective HLPC-1 coil in motor starter. Replace motor starter.
Table 9-14. Hoist Lube Pump Rear Motor Fault
9-17

MACHINERY MACHINERY

Dipper Trip motor lamp is not illuminat- Tripped circuit breaker. Reset breaker.
ed. Defective ASR2 relay. Replace ASR2 relay.
A 30 second delayed shutdown. Defective DTS1 coil in motor starter. Replace motor starter.
Table 9-15. Dipper Trip Motor Fault
9-18

MACHINERY MACHINERY
HOUSE HOUSE SWING LUBE HOIST LUBE DIPPER TRIP SWING LUBE
BLOWER BLOWER PUMP #1 PUMP MOTOR #1 PUMP #2
2300XPB ONLY

Swing Lube Pump motor lamp is not il- Thermal overload trip caused by:
luminated.
SLPC contactor.
Defective SLPC-1 coil in motor starter. Replace motor starter.
Table 9-16. Swing Lube Pump Rear Motor Fault (2300XPB Only)
9-19

MACHINERY MACHINERY

Dipper Trip motor lamp is not illuminat- Tripped circuit breaker. Reset breaker.
ed. Defective ASR2 relay. Replace ASR2 relay.
A 30 second delayed shutdown. Defective DTS2 coil in motor starter. Replace motor starter.
Dipper Trip motor lamp is not illuminat- Thermal overload trip caused by:
ed.
1. Improperly sized TOL elements Install proper elements.
A 30 second delayed shutdown.
2. Binding of dipper trip drum. Repair or replace according.
3. Excessive binding of latchbar/dutch- Repair latch bar so it opens on a single

man. This will cause the operator to re- cycle.
peatedly actuate the trip mechanism,
increasing the duty cycle.

DTSC contactor.
6. Dipper trip resistors set to incorrect Reset resistors to 2.45 ohms each.
ohmic value
Table 9-17. Dipper Trip Motor Fault
9-20
To check the ground fault circuits for the main, auxiliary, and CROWD/PROPEL AND HOIST/
field transformers simply press the appropriate pushbutton on PROPEL TRANSFER CABINET
the auxiliary cabinet door.
! WARNING
DANGER
To test the main transformer ground fault detection circuitry, the Before working in this cabinet, breaker DSCB
should be opened to remove 100 VDC power to con-
machine should be started up in either the ARMATURE TEST tactors. See schematics page 24.
or RUN modes of operation.
The transfer cabinet contains all of the necessary contactors to

direct power from the crowd and hoist converters to the propel
motors.
For field tests the machine need not be started.
Whenever the machine is in the propel mode of operation the

crowd and hoist motions are inoperative.
To test the auxiliary ground fault detection circuitry, the
auxiliary breaker ACCB should be closed. The machine need
Figure 9-3 shows the locations of the armature and field
not be started up. contactors and associated components.
9-21
100VDC Rectifier
Crowd Field Contactor
Propel Field Propel Field Contactor

Monitor Relay
Crowd Field
Monitor Relay
Hoist/Crowd Armature
Monitor Relay
Propel Armature
Monitor Relay
Hoist Armature Contactor
Propel #1
Armature Contactor
Crowd Armature Contactor
Propel #2
Armature Contactor
Figure 9-3. Transfer Cabinet
9-22
SECTION 10
INSTRUMENT OPERATION
INTRODUCTION
NOTICE
This section covers the operation of the various electronic
Where polarity is difficult to determine, the meter may
instruments commonly used to test the MkII Electrotorque
read backwards. No damage will be done if this oc-
system.
curs. Simply reverse the polarity with the switch.
Care must be exercised when using any test equipment. Follow 4. All DC ranges are read on the two black center scales; one
the directions carefully and proceed with all tests in an orderly directly above the mirror, the other below the mirror.
fashion. More detailed technical information about a particular
instrument is available from the manufacturer of the instrument.
OPERATION OF THE VOLT-OHM-

MILLIAMMETER
General
This section describes the operation of the VOM (Part Number
89Z495). Three operating modes (measurement of DC volts,
measurement of AC volts and measurement of DC resistance)
are frequently used when testing the MkII Electrotorque system
and are therefore covered in detail. The VOM is illustrated in
Figure 10-1.
MEASURING DC VOLTS
To measure DC volts with the VOM, proceed as follows:
1. Rotate the selector switch to the appropriate range for DC

volts determined from Table 10-1. Always start with the highest
range if in doubt as to the approximate voltage. In choosing
ranges, try to have the readings fall in the upper, or right hand,
half of the scale for greatest accuracy.
2. Plug the black test leads into the COM jack and the red lead
into the V-¾-A jack.
3. Connect the test probes across the voltage source (see Figure Figure 10-1. Volt-Ohm-Milliammeter (89Z495)
10-2). The red probe is positive.
10-1
DC
POWER SOURCE
N P
TO COM-JACK
- + TO V-¾-A JACK
TEST TEST
PROBE PROBE
LOAD
Figure 10-2. DC Test Probe Connections
5. With the slide switch in the V-¾-A position the following Measuring AC Volts
condition exists:
A. The full scale reading of the instrument is identical to that To measure AC volts with the VOM, proceed as follows:
indicated by the large range switch knob. Thus, with the
range switch knob at 3, note that the 3 volt range is read on 1. Set the polarity switch to plus (+).
the 300 volt scale simply by dropping two zeros (i.e.
dividing by 100). Other ranges are handled similarly by 2. Rotate the selector switch to the appropriate range for AC
adding or omitting zeros as required. volts determined from Table 10-2. Always start with the highest
range if in doubt as to the approximate voltage. In choosing
B. The meter sensitivity is 10,000 ohms per volt. ranges, try to have the readings fall in the upper, or right hand,
6. With the slide switch in the V-A/2 position, the following half of the scale for greatest accuracy.
conditions exist:
3. Plug the black test leads into the COM jack and the red lead
A. The instrument will read exactly half of the value indicated into the V-¾-A jack.
by the large range switch knob. Thus, with range knob set at
300, the meter actually will read 150.
NOTICE
B. The scale immediately above the mirror is used for 0-150
volts. With the range switch knob set on 60, the meter will The AC range up to and including 300 volts is compen-
read 30 volts full scale. Read this on the 300 volt scale by sated for frequencies from 35 Hz to 20 KHz.
dropping one zero (i.e. dividing by 10). Other ranges are
handled in a similar fashion. 4. Connect the test probes across the voltage source (see Figure
10-3).
C. The meter sensitivity is 20,000 ohms per volt with the slide
switch in the V-A/2 position. 5. With the slide switch in the V-¾-A position the full scale
7. MV with the slide switch to the right and 120 MV with the reading of the instrument is identical to that indicated by the
slide switch to the left, when placing the knob of the selector large range switch knob. Thus, with the range switch knob at
switch in the 0.12 or 1.2 DC MA ranges for either of the MV 1200, note that 1200 volts is read on the 12 volt scale by adding
readings. two zeros (multiply your reading by 100). There are scales
provided for 1.5, 3, 12, 60, 150 and 300. Other ranges are read
8. Use Figure 10-2 as a guide when measuring DC volts. similarly by adding or omitting zeros as required.
10-2
To Measure DC Volts Set Selector Set Slide Switch To Connect Test Leads in Jack Read On Multiply or Divide Scales
Switch To Marked Scale
.12 .12 MA V-A÷2 Position V-¾-A & COM 12 ÷100
.24 .12 MA V-¾-A Position V-¾-A & COM 12 ÷50
.3 .6 DCV V-A÷2 Position V-¾-A & COM 300 ÷1000
.6 .6 DCV V-¾-A Position V-¾-A & COM 60 ÷100
1.5 3 DCV V-A÷2 Position V-¾-A & COM 150 ÷100
3 3 DCV V-¾-A Position V-¾-A & COM 300 ÷100
6 12 DCV V-A÷2 Position V-¾-A & COM 60 ÷10
12 12 DCV V-¾-A Position V-¾-A & COM 12 Read Direct
30 60 DCV V-A÷2 Position V-¾-A & COM 300 ÷10
60 60 DCV V-¾-A Position V-¾-A & COM 60 Read DIrect
150 300 DCV V-A÷2 Position V-¾-A & COM 150 Read Direct
300 300 DCV V-¾-A Position V-¾-A & COM 300 Read Direct
600 1200 DCV V-A÷2 Position V-¾-A & COM 60 X10
1200 1200 DCV V-¾-A Position V-¾-A & COM 12 X100
3000 6000 DCV V-A÷2 Position 6000 DC & COM 300 X10
6000 6000 DCV V-¾-A Position 6000 DC & COM 60 X100
Table 10-1. Measuring DC Volts
To Measure AC Volts Set Selector Set Slide Switch To Connect Test Leads in Jack Read On Multiply or Divide Scales
Switch To Marked Scale
1.5 3 ACV V-A÷2 Position V-¾-A & COM 1.5 Read Direct
3 3 ACV V-¾-A Position V-¾-A & COM 3 Read Direct
6 12 ACV V-A÷2 Position V-¾-A & COM 60 ÷10
30 60 ACV V-A÷2 Position V-¾-A & COM 300 ÷10
150 300 ACV V-A÷2 Position V-¾-A & COM 150 Read Direct
600 1200 ACV V-A÷2 Position V-¾-A & COM 60 X10
1200 1200 ACV V-¾-A Position V-¾-A & COM 12 X100
3000 6000 ACV V-A÷2 Position 6000AC & COM 300 X10
6000 6000 ACV V-¾-A Position 6000 AC & COM 60 X100
Table 10-2. Measuring AC Volts
6. With the slide switch in the V-A/2 position the instrument so small as to be negligible. However, on the X1 range
will read exactly half of the value indicated by the large range a higher current is employed.
switch knob. Thus, with the range knob set at 300, the meter
actually will read 150 volts full scale. Other ranges are handled
in a similar fashion.
7. Use Table 10-2 as a guide when measuring AC volts. 1. Rotate the selector switch to the appropriate range for ohms
determined from Table 10-2.
MEASURING DC RESISTANCE
To measure DC resistance, with the VOM, proceed as follows:
2. To read ohms, place the slide switch in the right or V-&omc.-
A position. The polarity reversing switch on plus (+) position
NOTICE delivers plus (+) voltage on the V-¾-A jack, reversing the
When measuring resistance, a current is passed switch reverses this voltage which makes it particularly useful
through the unknown resistor. Generally this current is in the checking of diodes.
10-3
VAC
POWER SOURCE
TEST PROBE
TO V-¾-A JACK
TO V-¾-A JACK
RESISTOR
TO COM-JACK
TO COM-JACK
TEST PROBE
LOAD
Figure 10-3. Test Probe Connections Figure 10-4. DC Resistance Test Probe Connections
3. Plug the black test lead into the COM jack and the red lead 6. Use the basic 0-1K (0-1000 ohms) for reading all ohm ranges.
into the V-¾-A jack. Simply multiply the scale numbers by 10, 100, 1K, 10K, 100K
as indicated by the selector switch setting.
4. Short the test probes together and adjust the ¾-ADJ control
until the meter pointer reads 0 on the top red ohms scale.
5. Connect the test probes across the resistor (see Figure 10-4). NOTICE
If the resistor is wired in a circuit, disconnect one end of the
Since the scale of an ohmmeter is non-linear, the accu-
resistor before taking the reading.
racy of the reading cannot be expressed as a percent of
full scale. Ohmmeter accuracy is generally referred to
a linear scale such as a DC volt scale. Thus ±3% ohm-
NOTICE meter accuracy means an allowable ±1.8 division on
the 60 division DC scale. For example 2 ohms could
Each time an ohms range is changed, check the zero read from about 1.75 to 2.3 ohms and be within toler-
setting. ance.
To Measure Set Selector Set Slide Switch Connect Test Leads in Read On Multiply or Divide
Ohms Switch To To Jack Marked Scale Scales
0 to 1,000 X1 Ohms V-¾-A Position V-¾-A & COM Red Ohm 0-1000 Read Direct
0 to 10,000 X10 Ohms V-¾-A Position V-¾-A & COM Red Ohm 0-1000 x10
0 to 100,000 X100 Ohms V-¾-A Position V-¾-A & COM Red Ohm 0-1000 x100
0 to 1,000,000 X1000 Ohms V-¾-A Position V-¾-A & COM Red Ohm 0-1000 X1000
0 to 10 Meg X10K Ohms V-¾-A Position V-¾-A & COM Red Ohm 0-1000 X10,000
0 to 100 Meg X100K Ohms V-¾-A Position V-¾-A & COM Red Ohm 0-1000 X100,000
Table 10-3. Measuring DC Resistance
10-4
OPERATION AND FEATURES OF THE
DIGITAL MULTIMETER (89Z514D12)
General
The FLUKE model 23 digital multimeter is recommended for
use when making electrical measurements on the Electrotorque
drive systems.
The location of the main components are shown in Table 10-5.
Features
Battery Power
The multimeter is powered by a single 9 volt battery which is
expected to last 2,000 hours, or 2 years. A special circuit will
power down the meter after a given time period of non-use.
Inputs
There are four input jacks on this meter:
Common: All signals are referenced to this jack.
Volts, Ohms, Diode Check:Measures these inputs.
10 Amp: Can accept up to 10 Amps, AC or DC,

depending on the position of the
selector switch.
300 ma: Can accept up to 300 ma AC or DC Figure 10-5. Digital Multimeter (89Z514D12)
depending on the position of the
selector switch. Auto Ranging
Bar Graph Display

Auto ranging speeds up the use of the meter by quickly selecting
Because all digital multimeters have a sampling rate at which the proper range for the measurement being applied.
they sample and display the measurement, there is a delay in
these readings.
Manual ranging is included.
The bar graph samples 10 times faster than the digital display
and is handy for checking capacitor charge/discharge rates or
other dynamic measurements.
Diode Test, Continuity, Resistance
Polarity
The polarity of the signal being measured will be displayed by Wiring or diode checks can be made with the selector switch set
a — sign in the upper right hand corner of the display. If the in the diode symbol position. A continuous tone signals
signal is +, no sign will be displayed. Make sure your probes are continuity, a beep signals a forward biased diode or transistor
connected properly to the expected polarities. junction.
10-5
Desired Measurement Input Connection Switch Position
AC Voltage com -V ¾ V
DC Voltage com -V ¾ V
Milli-Volts com -V ¾ 300 mV
Ohms com -V ¾ ¾
Diode Check com -V ¾
AC Current com -10A or 300mA A
DC Current com -10A or 300mA A

Table 10-4. Multimeter Connections and Switch Position
Touch Hold 1. Grasp the meter with both hands and pull the spring clip back
slightly with the thumbs.
This feature allows automatic measurements while watching
the probes or the circuit under measurement. The meter captures 2. Exert upward pressure with the first fingers and lift the meter
the measurement, beeps, and locks it in the display until you are from its seating (see Figure 10-7).
ready to use it.
NOTICE
Input Impedance
Care should be taken that only a direct pull is exerted
The input impedance of the meter is 10 meg-ohms on all ranges. on the meter, and under no circumstances should any
leverage be employed. Breakage of the cylindrical por-
OPERATION OF THE TONG TEST

AMMETER
General
The tong test ammeter (Part Number 89Z367) is a portable
instrument that measures current flowing in a circuit without
making an electrical connection to it (see Figure 10-6). The tong
tester consists of an insulated, laminated sheet tongs and one or
more removable bakelite scale ranges. The tong tester will
measure DC as well as AC. When used on DC the accuracy is
about one-half of that obtained on AC.
Meter Operation
REMOVING THE SCALE RANGE. When taking a current
reading, if the needle goes off scale or does not move
sufficiently to give a good reading, it is necessary to select
another scale of suitable range. To change scales, proceed as Figure 10-6. Tong Test Ammeter (89Z367)
follows:
10-6
tion of the molding could result if improper force is ex-
erted.
USE ON DIRECT CURRENT. For the most accurate DC

measurement, proceed as follows:
1. Just before taking a DC reading, press the trigger of the tong
tester all the way and then release it sharply. This reduces the
error due to hysteresis.
2. For more accurate DC measurements the current should be
measured in both directions of current flow. The mean of the
two current readings should be taken and then the correction
factor of the instrument should be added or subtracted,
whichever the case may be.
NOTICE
The correction factor is indicated on the lower left side
of dial.
Lowering the Range of a Meter Figure 10-8. Lowering Range
When measuring the current flow through a flexible conductor,

the range can be lowered if it is possible to double up the TESTER
conductors so as to make two or more loops around the tong
tester jaws. For example, if a conductor is carrying a current of
about 8 amperes and a 50 ampere range is available to measure General
the current, placing three turns through the tongs will give an
indication of 24 amperes. Then the actual current, which in this
case is 8 amperes, is equal to the reading divided by the number Proper testing of thyristors (SCR’s) requires the use of a
of loops or turns (see Figure 10-8). thyristor tester. The use of the thyristor tester (Part Number
89Z511D1) is described in the following paragraphs and is
illustrated in Figure 10-9. Table 10-5 indicates the tests that can
OPERATION OF THE THYRISTOR be performed and the test determinations.
! CAUTION
DANGER
When performing the following tests the manufac-
turer’s maximum rated specifications for the thy-
ristor must not be exceeded.
Tester Operation
To test thyristors using the thyristor tester, proceed as follows

(see Figure 10-9):
! WARNING
DANGER
Be certain that the power switch is in the OFF posi-
Figure 10-7. Meter Removal tion before inserting a thyristor in the test fixture or
removing the thyristor from the test fixture.
10-7
Figure 10-9. Thyristor Tester (89Z511D1)
1. Place power switch S1 in the OFF position. conducting in the forward direction when the proper gate
voltage is applied.
2. Mount the thyristor in the test fixture.
5. Place the voltage adjust control in the zero position.
3. Connect the cathode lead of the thyristor to J3 (red terminal).
4. Connect the anode lead of the thyristor to J1 (yellow Forward Leakage Test
terminal).
5. Connect the gate lead of the thyristor to J2 (white terminal). GENERAL. The forward leakage test is used to determine if a
breakdown of the thyristor is taking place when a high voltage
is applied and the gate is not fired. As the potentiometer is
NOTICE moved to a more positive point the leakage voltage meter
reading should increase (see Figure 10-11). The leakage current
Consult Table 10-6 for thyristor test data. meter should not exceed the values given in Table 10-6. Care
should be taken not to exceed the manufacturer’s maximum
Gate Test peak forward voltage rating of the thyristor. An increase in
GENERAL. The cathode to anode junction is forward biased

(see Figure 10-10). As the arm of the potentiometer is moved to
a more positive point, the gate current and gate voltage meters
should show an increase. The conduction indicator lamp should GATE
also light. Failure of any of the above indications would indicate CURRENT
a defective thyristor. A
TESTING. To perform the gate test, proceed as follows:

GATE V
1. Place S2 in the gate test position. VOLTAGE
2. Turn the voltage adjust control to the zero position.

CONDUCTION
3. Place S1 in the ON position. Gate current and gate voltage INDICATOR
meters should read zero and the conduction indicator lamp
should be OFF.
4. Advance the voltage adjust control. The gate voltage and gate
current meter should start to indicate. The conduction indicator Figure 10-10. Gate Test Circuit
lamp should also light. This indicates that the thyristor is
10-8
TEST PERFORMED TEST DETERMINATIONS
Gate Test 1. Condition of the thyristor.
2. Gate voltage required to fire the thyristor to cause conduction.
3. Gate current required to cause the thyristor to conduct.
Forward Leakage 1. Forward leakage current through the thyristor when the gate is not fired.
2. Allows for testing of the thyristor at the maximum rated peak voltage.
Reverse Leakage 1. Indicates a breakdown of the cathode to anode junction under a biased condition with the
gate to cathode circuit open.
2. Permits testing of the thyristor at the manufacturer’s maximum reverse voltage rating
Table 10-5. Thyristor Tests
leakage current with an increase in leakage voltage would 3. Advance the voltage adjust control until the leakage voltage
indicate a defective thyristor. meter indicates maximum peak reverse rating of the thyristor.
The leakage current meter must not exceed the values given in
TESTING. To perform the forward leakage test, proceed as Table 10-6. Failure to meet specifications indicates a defective
follows: thyristor or one breaking down at other than its maximum
reverse voltage rating.
1. Place S2 in the forward leakage position.
2. Depress the leakage test button and hold it in the depressed
4. Return the voltage adjust control to zero.
position for this test.
3. Advance the voltage adjust control until the leakage voltage
5. Release the leakage test button.
meter reads the maximum rated peak forward voltage rating of
the thyristor. The leakage current reading must not exceed the
values given in Table 10-6. Failure to meet specifications 6. Place S1 in the OFF position.
indicates a defective thyristor or one breaking down at other
than its rated forward voltage rating.
7. Disconnect the thyristor leads from the thyristor tester.
4. Return the voltage adjust control to zero.
5. Release the leakage test button. 8. Remove the thyristor from the thyristor test fixture and
replace it in the circuit if all tests are correct.
Reverse Leakage Test
GENERAL. This test is used to determine if a thyristor is failing
under reverse biased conditions, when the gate is not triggered
(see Figure 10-12). An increase in leakage current with an
increase in leakage voltage would indicate a defective thyristor.
Care should be taken during this test to not exceed the
manufacturer’s maximum peak reverse voltage rating of the
V
thyristor. LEAKAGE
VOLTAGE
A
TESTING. To perform the reverse leakage test, proceed as LEAKAGE LEAKAGE
follows: CURRENT TEST
1. Place S2 in the reverse leakage position.

2. Depress the leakage test button and hold depressed for this Figure 10-11. Forward Leakage Test Circuit
test.
10-9
2. All testing requires the use of the Thyristor Test Fixture,
89Z511, all devices under test being properly mounted in the
related clamping fixture.
V
LEAKAGE 3. Optional test aid — use an oscilloscope with line triggering
VOLTAGE
A in conjunction with the test fixture for measuring peak leakage
LEAKAGE
CURRENT currents. Terminals labeled "current" and "common" are
provided on the fixture for this purpose. Assume 10mA/volt
LEAKAGE when making oscilloscope measurements. If an oscilloscope is
TEST not available, the maximum average criteria must be used;
average readings being obtained using the fixture meter.
Figure 10-12. Reverse Leakage Test Circuit
4. It is also recommended that the forward conduction
THYRISTOR TEST DATA characteristics of the diodes be checked. This can be done as
follows:
Purpose A. Clamp the device to be tested in the clamping fixture.
To define specific criteria by which a given power B. Connect the anode terminal to the "white" terminal on the
semiconductor device can be judged as acceptable for service. test fixture (J2).
Conditions C. Connect the cathode terminal to the "red" terminal on the test
fixture (J3).
All of the criteria in Table 10-6 assumes the following

conditions: D. Increase "gating" control until 150mA gating current is
noted.
1. All test conducted at room temperature - approximately +25°
C (78° F). E. Read corresponding voltage.
PART NO. TYPE TEST PARAMETER TEST REQUIRMENTS

75Z727D14 Thyristor all motion Gate Voltage 3.0 V Maximum
converters Gate Current 400 mA Maximum
Leakage Current:
Forward at 2200V 15 mA Max, Average, 100 mA Max. Peak
Reverse at 2200V 15 mA Max, Average, 100 mA Max. Peak
75Z727D13 Thyristor R.P.C. and Gate Voltage 3.0 V Maximum
diverters Gate Current 400 mA Maximum
Leakage Current:
Forward at 3400V 10 mA Max, Average, 100 mA Max. Peak
Reverse at 3400V 10 mA Max, Average, 100 mA Max. Peak
75Z935D1 Diode R.P.C. Leakage Current:
Reverse at 3500V 3 mA Max. Average, 15 mA Max Peak
Forward Current 150 mA Minimum
Forward Drop 1.0V Maximum
0.5V Minimum
75Z935D1 Diode Divereters. Leakage Current:
Reverse at 2000V 10 mA Max. Average, 50 mA Max Peak
Forward Current 150 mA Minimum
Forward Drop 1.0V Maximum
0.5V Minimum
Table 10-6. Thyristor Test Data
10-10
OPERATION OF THE OSCILLOSCOPE The electronic process of forming, focusing, accelerating,
controlling and deflecting the electron beam is accomplished by
the following principal elements of the CRT: the electron gun
Introduction consisting of a heated cathode, a grid, a focusing anode, and an
accelerating anode; a deflection system, for controlling the
The following paragraphs cover the basic operation of the direction of the beam emanating from the electron gun; a
Model 214 and Model 212 (Part Number 89Z515D1) fluorescent screen, for visually indicating the movement
oscilloscopes. Oscilloscopes are manufactured in various sizes,
imparted to the electron beam; and an evacuated glass bulb,
shapes, models and price ranges. However, they all perform the
which contains all the above elements of the CRT. Partially
same basic functions. Oscilloscopes are basically peak to peak
voltmeters. A visual presentation of the voltage being measured covering the inside of the glass bulb is Aquadag (graphite)
is presented on the oscilloscope display. Oscilloscopes have a coating which provides a return path for electrons at the same
very high impedance and cause very little loading effect on the time serves to shield the electron beam electrostatically.
circuit under test. Table 10-7 is a comparison of the capabilities
of an oscilloscope and a volt-ohmmeter.
Description The oscilloscope probe is the connection between the

oscilloscope and the component being tested (see Figure 10-
The principal components of a basic oscilloscope include a 14). A simplified schematic diagram of the probe is shown in
cathode- ray tube, a sweep (sawtooth) oscillator, deflection Figure 10-15. The input impedance of the probe is determined
amplifiers (horizontal and vertical), and suitable controls, primarily by R1 and C1. The value of R1 and C1 will vary
switches, and input terminals for the proper operation of the unit depending on the attenuation factor of the probe. The ground
(see Figure 10-13). reference switch is found on some probes. It permits selecting
of a reference point on the oscilloscope trace. When the switch
The heart of an oscilloscope is the cathode-ray tube (CRT). This
is closed, the input to the scope is placed at the common
is a special type of electron tube in which electrons emitted by
reference (ground). The input to the oscilloscope is now zeroed.
a heated cathode are focused and accelerated to form a narrow
beam having high velocity. The beam is then controlled in Capacitor C2 is adjustable and is used to compensate for the
direction and allowed to strike a florescent screen, whereupon inductive and capacitive characteristics of the probe body,
light is emitted at the point of impact and produces a visual connecting lead, and input to the oscilloscope vertical
indication of the beam position. deflection amplifiers.
OSCILLOSCOPE MEASUREMENTS VOLT-OHMMETER MEASUREMENTS

1. DC Voltage 1. DC Voltage
2. Peak to peak AC voltage 2. AC rms voltage
3. Pulse voltages 3. Current
4. Time of waveform 4. Resistance
5. Frequency of waveform
6. Very small amplitudes of signal voltage
7. Very high frequency signal voltages
8. Distortion of the waveform
Table 10-7. Comparison Oscilloscope - VOM
10-11
VERTICAL GAIN
VERTICAL CATHODE
INPUT VERTICAL RAY
DEFLECTION TUBE
AMPLIFIER
+ VERTICAL SCREEN
POSITIONING
R3
SYNC SELECTOR -
VERTICAL DEFLECTION PLATES
SYNC AMPLIFIER HORIZONTAL

DEFLECTION PLATES
SWEEP GENERATOR
HORIZONTAL
EXT INPUT
SYNC S4
SELECTOR
COARSE
SWEEP + HORIZONTAL
FREQUENCY INTENSITY FOCUS POSITIONING
FINE R1 R2 R4
FREQUENCY AMPLIFIER HORIZONTAL
GAIN -
+300V +1,100V
HORIZONTAL HORIZONTAL LOW VOLTAGE HIGH VOLTAGE

TEST DEFLECTION POWER POWER
SIGNAL INPUT
AMPLIFIER SUPPLY SUPPLY
TO 6 VOLTS AC
110 VOLT
60 CYCLE LINE
Figure 10-13. Oscilloscope Operation
MODEL 212 OSCILLOSCOPE Operation

(89Z515D1)
The controls and connectors necessary for operation of the
Model 212 are located on the right side of the instrument (see
Figure 10-16). The power (battery) indicator is on the front
Description panel. A description of each control and connector is given in
Table 10-8 through Table 10-12.
The Model 212 oscilloscope is a dual channel portable
oscilloscope using all solid state circuitry. The small size makes
it an extremely portable instrument, ideally suited for mine
NOTICE
operations. An asterisk (*) in front of a control indicates that the
item is to be adjusted during calibration procedures
only.
The Model 212 scope is operated from AC line voltage or from
internal rechargeable batteries. The batteries are recharged from
the AC power line by the internal battery charging system. Typical Model 212 oscilloscope connections as related to the
Electrotorque system are as follows:
Additional information regarding the technical aspects of this Use the connections illustrated in Figure 10-17 for monitoring
oscilloscope may be found in the Model 212 oscilloscope the current feedback signals on hoist, swing or crowd armature
manual. frames. Use the following scope settings and connections:
10-12
Figure 10-14. Probe Components
A. Power............................................................................... ON Operation
B. Vertical sensitivity ........................................ 5 volts/division
C. Horizontal sweep ....................................5 millisecs/division
D. Input coupling.................................................................. DC The controls necessary to operate the Model 214 oscilloscope
E. Trigger source .............................................................COMP are located on the front and right side of the instrument.
F. Probe tip .............................................................. Test point 6
G. Ground tip......................................................... Test point 20 Because the controls on the side are identical to the Model 212
described under the “Model 212 Oscilloscope (89Z515D1)”
topic on page 10-12, only the functions of the front panel
MODEL 214 OSCILLOSCOPE controls will be described here.
(89Z515D4)
Ready Light
General
Indicates sweep has been reset and a single display will be
The Model 214 STORAGE oscilloscope is a dual channel presented upon receipt of an adequate trigger signal.
portable oscilloscope using all solid state circuitry. The small
size makes it an extremely portable instrument, ideally suited
for mine operations (see Figure 10-18). Single Sweep
Additional information regarding the technical aspects of this When pressed, the sweep operates in the Single Sweep mode.
instruments may be found in the manufacturers manual for the After a sweep is displayed, further sweeps cannot be presented
Model 214. until the RESET button is pressed.
10-13
R1 R2
PROBE TIP
C1
R3
TO
OSCILLOSCOPE
GROUND
REFERENCE C2
SWITCH
COMMON LEAD
(GROUND)
PROBE BODY COMPENSATOR
Figure 10-15. Probe Schematic Diagram
Figure 10-16. Model 212 Oscilloscope Controls and Connections
10-14
Figure 10-17. Current Feedback Connections and Waveforms
CONTROL FUNCTION
Intensity Controls brightness of CRT display.
*Focus A screwdriver adjustment to obtain a well-defined display.
Table 10-8. Display Controls
10-15
CONTROL FUNCTION
Volts/Division Selects vertical deflection factor (vertical VARiable control must be CAL position for
indicated deflection).
Input Coupling Selects the method used to couple the channel input signal to the vertical amplifier
system. The DC component of the input signal is blocked. Vertical amplifier input sig-
AC nal is grounded. The applied input signal is connected to ground through a one me-
GND gohm resistor to provide a precharge path for the AC input coupling capacitor. All
DC components of the input signal are passed to the vertical amplifier system input.
* Step Attenuation Balance A screwdriver adjustment to balance the vertical amplifier system for minimum trace
shift when switching deflection factors.
CH 1 Position Controls the vertical position od the channel 1 trace . OFF detent turns the channel off.
CH 2 Position Controls the vertical position od the channel 2 trace . OFF detent turns the channel off.
Volts/Division Variable Provides a continuously variable deflection factor between the calibrated settings of
the VOLT/DIV Switch for the appropriate vertical channel.
* Vertical Gain Screwdriver adjustment to set the gain of the vertical amplifier system.
Table 10-9. Vertical Deflection Controls (Model 212)
CONTROL FUNCTION
Horizontal Magnifier Provides contiuously variable sweep magnification to a maximum of approximately
five times the sweep rate indicated by the SEC/DIV switch.
* Horizontal Gain A screwdriver adjustment to set the basic gain of the horizontal amplifier system.
Horizontal Position Selects horizontal sweep rate (HORIZ MAG must be in CAL position for indicated
sweep rate). X-Y position allows for X-Y operation: CH 2 supplies the vertical deflec-
tion and CH 1 the horizontal deflection.
* Sweep Calibration A screwdriver adjustment to provide calibrated sweep timing.
Table 10-10. Horizontal Deflection Controls (Model 212)
CONTROL FUNCTION
Automatic Preset A screwdriver adjustment to set the AUTO PRESET trigger point for automatic trigger
operation.
Trigger Source Selects the source of the trigger signal.
COMP The sweep is triggered from a sample of the vertical deflection signal after the vertical
switching.
CH 2 The sweep is triggered from a sample of the vertical deflection signal before the ver-
tical switch and only from CH 2.
EXT The sweep is triggered from the signal applied to the EXT TRIG banana jack.
Level/Slope Selects the amplitude point and the slope of the trigger signal on which the sweep is
triggered. When the indicator dot is to the left of the center, the sweep is triggered on
the positive-going slope of the trigger signal; to the right of center, on the negative go-
ing slope.
When the LEVEL/SLOPE control is set to the AUTO PRESET detent the sweep is au-
tomatically triggered at a preset level on the positive-going slope.
Table 10-11. Trigger Controls (Model 212)
10-16
CONTROL FUNCTION
External Trigger Banana jack for input of an external trigger signal
Common Banana jack to establish common ground between the 212 and the external sig-
nal source or equipment under test.
! WARNING
DANGER
Common and probe ground straps are electrically connected. Therefore,
an elevated reference applied to any is present on each - as indicated by
the yellow warning bands under the probe retractable hook tips.
Power Controls power to the instrument. Does not interrupt charging current to the in-
ternal batteries when the instrument is connected to an ac line voltage.
Power (battery) indicator A red light to indicate when the instrument is on. When light extinguishes, less
than ten minutes of operating life remain.
Table 10-12. Miscellaneous Controls (Model 212)
Reset leaving the CRT target fully stored for five to ten min-
utes. This procedure may be repeated to refresh the tar-
When pressed and in the Single Sweep mode, a single display get in applications requiring maximum stored writing
will be presented after correct triggering. After the sweep is rate.
completed, the RESET button must be pressed again before
another sweep can be displayed.
Store
NOTICE
After sustained use (30 minutes or more) of the instru- When pressed, the CRT operates in the Storage mode. With the
ment in the Store mode with nothing written, the writ- button out, the CRT operates in the conventional, NONSTORE,
ing speed may be reduced. It may be improved by mode.
Figure 10-18. Model 214 Oscilloscope
10-17
Erase
Momentary contact switch, that when pushed and released
erases a Stored display from the CRT.
Volts/Div
Selects the vertical deflection factor in a 1-2-5 sequence
(vertical VARiable must be in the CAL position for indicated
deflection).
Power (Battery)
A Red light to indicate when the instrument is on. When light
extinguishes, battery charge is low and about five minutes of
operating life remains.
MODEL 97 COMBINATION
OSCILLOSCOPE AND DIGITAL
VOLTMETER
The “Fluke” Model 97 combination oscilloscope and digital
voltmeter is recommended for use when examining the various
waveforms or measuring voltage values. Refer to Figure 10-19.
Consult your “Fluke” Scopemeter users manual for safety Figure 10-19. Model 97 Combination Oscilloscope and Digital
procedures and measuring features.
Voltmeter
OPERATION OF THE BRUSH 4. Chart speed motor

RECORDER
Brush Recorder Operation
General
Refer to Figure 10-21 and Table 10-13 prior to operating the
This topic describes the general operating procedures for the
brush recorder. To operate the brush recorder, proceed as
Model 220 (Part Number 89Z471) brush recorder. The brush
follows:
recorder (chart recorder) is a general purpose test instrument. It
is extremely useful when a waveform analysis is required. It
provides a permanent record of the waveforms under test to be 1. Place the power switch in the ON position.
used for analysis at a later date or for comparison records. It also
permits the technician or engineer to analyze complex
waveforms which are producing very fast changes. NOTICE
With the power OFF the pens are deflected to an off the
NOTICE chart position. When the power is ON the pens are
locked in a center chart position (STOP button de-
The 89Z471 brush recorder is a 60 Hz recorder. If a 50 pressed). Pressing the STOP button during a chart re-
Hz recorder must be used, its part number is 89Z472. cording will result in the pens returning to the center
chart position.
The brush recorder has four basic sections (see Figure 10-20).
1. Power supply and amplifier 2. With the power on, the pen position adjustments are made as
follows:
2. Sensitivity control
3. Pen motor 1. Set the chart speed to 1 mm/sec.
10-18
SENSITIVITY
(ATTENUATOR) PREAMP AMP PEN
CONTROL MOTOR
CHART
PAPER
1 2 G
INK POWER
SOLENOID SUPPLY
TRANSMISSION
MOTOR
MOTOR/TRANSMISSION
SPEED
SELECTOR
LINE POWER
Figure 10-20. Brush Recorder Block Diagram
2. Unlock the position control.

NOTICE
3. Using the position control, center the pens on the chart.
Each small division on the chart is equal to the setting
4. Lock the position control after the pens have been centered. of the sensitivity switch, i.e., with the sensitivity
switch set at 500 m/volts each small division is equal
to 500 m/volts (see Table 10-22).
5. Adjust the sensitivity control for the desired sensitivity. When
measuring signals of unknown amplitude the control should be
set to 10 volts/division. Sensitivity can then be increased to the 6. Adjust the speed controls as follows:
desired level, as follows:
A. With the chart speed set at 1 mm/sec each small division
SMALL MAJOR equals 1 second.
DIVISION DIVISION
EQUALS EQUALS B. With the chart speed set a 5 mm/sec each small division
equals 200 msec. Each major division equals 1 second.
10 V .................................................................................... 50 V
5 V ...................................................................................... 25 V C. With the chart speed set at 25 mm/sec each small division
2 V ...................................................................................... 10 V equals 40 msec. Each major division equals 200 msec.
500 m/v.............................................................................. 2.5 V
200 m/v................................................................................. 1 V D. With the chart speed set at 125 mm/sec each small division
100 m/v..........................................................................500 m/v equals 8 msec. Each major division equals 40 msec.
10-19
line crosses the chart center, approximately 25 feet of paper
remains. To change the chart paper, proceed as follows:
1. Press the chart STOP button.
2. Turn the recorder off.
3. Grasp the pull bar on the bottom of the writing table and pull
it out and up to place the writing table in an open position (see
Figure 10-23).
4. Hold the paper supply core and shaft and pull down on the
paper supply release lever and remove the paper supply core and
shaft (see Figure 10-25).
5. Unscrew the paper core from the supply roll shaft and discard
the paper core.
6. Slide a new roll of paper onto the supply roll shaft.
NOTICE
Check to be sure that the flange of the shaft is at the
right side adjacent to channel 2 on the chart paper and
that the paper unwinds from the top of the roll.
7. Screw the supply roll shaft into the paper core so that the
Figure 10-21. Model 220 Brush Recorder (89Z471)
flange is snug against the paper core.
Changing Chart Paper 8. Insert the flanged end of the paper supply roll shaft into the
shaft mounting holes in the writing table assembly, and push up
The last 50 feet of all brush chart paper is identified by a blue on the release lever to lock the shaft into position (see Figure 10-
line moving from the right edge to the left edge. When the blue 24).
CONTROL FUNCTION
Power Controls the AC power applied to the brush recorder.
Chart Speed mm/sec Controls the speed of the chart motor
Stop Chart is not moving
1 mm/sec Chart is moving at 1 millimeter per second
Mark Event Places an event marker on the outboard side of the chart when pressed. Very useful
for marking a change of signal. Each channel has its own event marker.
Sensitivity Determines the sensitivity of the pen motor amplifiers. Moves in steps from a maxi-
mum of 1 millivolt per divisionto a minimum of 10 volts per division. Each channel
sensitivity can be adjusted independently.
Sensitivity X1 Can be used to produce a variable sensitivity. Calibrated only in the X1 position.
Position Used to center the trace on the chart paper. Each channel can be positioned individ-
ually.
Table 10-13. Brush Recorder Controls
10-20
Figure 10-22. Typical Brush Recording
9. Check to be sure the left end of the supply roll shaft is seated 10. Feed the paper over the writing bar, through the slot in the
in the writing table assembly and that the supply roll shaft front of the writing table, behind the pressure roll and out the
rotates freely. front of the writing table (see Figure 10-27).
! CAUTION
DANGER NOTICE
Use care during paper threading not to damage the Refer to the paper threading diagram on the side of the
pens. writing table assembly.
Figure 10-23. Opening The Writing Table Figure 10-24. Loading Paper Supply
10-21
Figure 10-25. Removing Paper Supply
11. Slowly close the writing table assembly while gently pulling Figure 10-27. Threading Paper
on the paper. When friction resists rotation of the paper roll, pull
the paper taut, center it on the writing table, and close the
writing table.
Measurements
COMMON CIRCUITS
NOTICE ! WARNING
DANGER
Check to be sure the writing table is properly engaged The recorder may be at a high potential. Use 3-2
by pressing on both sides of the table. adapter on the power line plug to isolate the brush
recorder from the machinery ground.
12. Turn the recorder on and operate it at 125 millimeters per When the brush recorder is to be used on common circuits, the
second until about two feet of chart paper has run through. This grounding straps should be connected between terminals G and
should align the chart paper. terminal 2 on both channels (see Figure 10-26). A test lead may
Figure 10-26. Common Circuit Grounding Straps
10-22
Figure 10-28. Monitoring Two Sources with a Common Connection
then be connected between either of the G or number 2 of the CIRCUITS WITH DIFFERENT REFERENCES
brush recorder to the common of the circuit under test (see
Figure 10-28).
! WARNING
DANGER
The recorder may be at a high potential. Use 3-2
! CAUTION
DANGER adapter on the power line plug to isolate the brush
recorder from the machinery ground.
Insure that the circuit under test has the same com-
mon reference for both signals before attempting to The brush recorder can also be used on circuits which are not
operate the brush recorder. common. Special care is required to insure that the grounding
10-23
Figure 10-29. Disconnection of Grounding Straps
Figure 10-30. Monitoring Two Sources with Different References
10-24
strap between terminals 2 and G of both channels is removed. eliminates ink and conventional mechanical style. The
To accomplish this, loosen the knobs on terminals G and 2, slide eliminations of mechanical components and inks results in a
the grounding strap down (see Figure 10-29). It is not necessary highly reliable recorder that produces printed waveforms that
to remove the grounding strap from the recorder. The signal precisely represent the original signals. The recorder can create
inputs to channel 1 and 2 are applied to terminals 1 and 2 of the either of two possible grids and simultaneously print
respective channels (see Figure 10-30). waveforms.
! CAUTION
DANGER
Normal shovel operation requires an ungrounded The result: total correlation between the recorded waveform and
brush recorder. the selected grid. Chart drift error is eliminated. Whether
creating two 50-division grids or a single 50-division
DASH II OPERATIONS MANUAL overlapping grid, the recorder prints accurate amplitudes and
(MODEL MT) sharp waveform traces. The recorder frequency response range
is DC to 500 Hz.
Recorder Highlights
The DASH II is a portable, two-channel, high-speed, direct-
writing recorder. (See Figure 10-31). Enclosed in a rugged The DASH II uses a crystal-referenced stepper motor to
aluminum case, the DASH II is constructed for reliability and advance the paper through the recorder. The stepper motor
accuracy. The DASH II can be used as both a dependable field provides seventy chart-paper speeds ranging frm 1 mm/min to
recorder and a sophisticated laboratory recorder. The high- 100 mm/sec. The pages that follow list the physical and
resolution thermal array printhead employed by the DASH II functional specifications of the DASH II.
Figure 10-31. Astro-Med’s DASH II Model MT Recorder
10-25
Figure 10-32. Signal Input Connections
General Information battery charger. The batteries are placed at the bottom of the
case in formed, protective polyurethane foam. A neoprene
Before actually using your DASH II recorder in any given task, gasket around the top of the case seals the recorder when the
you should familiarize yourself with the recorder’s physical cover is closed. This helps to ensure a dust and moisture
controls, indicators, and connections.
resistant environment for the closed recorder.
The following paragraphs will introduce you to the basic
hardware features of the recorder. Understanding the purpose Front-Panel Signal Input Connections
and function of each feature will allow you to quickly master
this versatile and user-friendly instrument. To accommodate signal input, the DASH II is equipped with
two front-panel 15-pin D-shell connectors labeled CHANNEL
You should also acquaint yourself with the controls of the two 1 and CHANNEL 2 and two groups of 5-Way binding posts.
signal conditioners required to operate the recorder. Refer to the Both types of inputs are used to carry signals from an external
Operations Manuals that come with your signal conditioners for source to the two signal conditioners installed in the recorder
information regarding signal-conditioner features. card cage. However, both types of inputs :hp2.cannot be
used:ehp2. at the same time. Depending upon your application,
Case Description one kind of input connector may be more convenient than the
other.
The DASH II recorder is housed, protected, and carried in a
rugged 14-gauge, drawn aluminum case. The dimensions of the As previously discussed, two 15-contact D-shell pin housings
case are 12"H x 10"W x 13.25"D. The case has a removable
are supplied or used with the recorder’s front panel D-shell
cover.
connectors. The wiring required by the pin housings depends on
The removable cover is attached to the case by three separable the signal conditioners being used in the recorder. You will need
pin hinges and secured by two front latches. This makes the to refer to the Operation and Service Manuals that accompany
cover easy to remove from the base. your ASC-900 Series signal conditioners for information
regarding the wiring of the pin housings.
The AC power cord used for AC line operation is wound around
a cord winder inside the cover for storage.
Like the 15-contact D-shell input connectors, the 5-Way
The base that houses the recorder contains the power supply, binding post inputs are used to input signals into the signal
two rechargeable gel-type batteries (factory installed), and a conditioners. However, the binding post inputs cannot be used
10-26
Figure 10-33. Front Panel Controls
with all signal conditioners. Banana plugs are commonly used channel number screened on the panel: SIGNAL INPUT
in conjunction with the 5-Way binding posts. Banana plugs are CHANNEL 1 and CHANNEL 2.
not supplied with your recorder. Please supply them if they are
The 5-Way binding posts located directly above the signal
required for a specific application. (See Figure 10-32).
conditioners provide an alternative to the D-Shell connectors
for signal input. However, the binding posts cannot be used with
Front Panel Controls all signal conditioners. In addition, you must supply banana
jacks for use with the binding posts.
Figure 10-33 is provided to simplify the following description
2. EXTERNAL MARKER Jack
of the switches and front-panel features of the DASH II. The
features in the illustration are numbered for convenient
reference in the paragraphs that follow. The paragraphs below The EXTERNAL MARKER jack, located in the upper left
define the function of each DASH II front-panel feature. The corner of the front panel, accepts a 1/4" three-conductor phone
numbered paragraphs below correspond to the numbered call- plug provided with the recorder. Insertion of the phone plug
outs of Figure 10-33. causes an external event marker line to be printed continuously
at the left edge of the chart paper. Appendix D provides
1. Signal Input representative samples of DASH II charts that identify the chart
features discussed here and throughout this manual. The
For the Purpose of signal input, the DASH II is equipped with external event marker line will only appear when the phone plug
two 15-in D-shell connectors and two 5-Way binding posts. is inserted in the EXTERNAL MARKER jack. (The external
Both inputs carry signals from an external source to the two event marker line is separate and distinct from the system event
signal conditioners installed in the recorder. However, the marker line continuously printed to the left of the channel 2
inputs cannot be used simultaneously. Use the method of signal grid.) The phone plug allows you to input external TTL lows
input that best suits your application. and provides a mechanic for the implementation of switch
closures. Either of these alternatives provides an externally
The two 15-pin D-shell connectors are located to the left of the generated means of switch closures. Either of these alternatives
signal conditioners. They are vertically oriented, one above the provides an externally generated means of marking the location
other. Each connector is easily identified by the corresponding of data that you consider significant by causing the event marker
10-27
line to deflect to the left. event marker line returns to its original the digit and one is below the digit. Pressing the top pushbutton
position when the switch is released or when the TTL low decreases the digit. Pressing the lower pushbutton increases the
concludes. The marker disappears when the phone plug is digit.
removed from the jack.
3. REMOTE START/STOP Jack The TIME/DATE SET switch is used to program the recorder’s
internal time and date.
The REMOTE START/STOP jack accepts a 1/4" three-
conductor phone plug identical to that of the EXTERNAL The ID1/ID2 SET switch causes the 4-digit, user-specified
MARKER jack. This jack is also provided with your recorder. identification number to be printed in either of the recorder’s
With this phone plug wired and inserted into the REMOTE two interchannel buffers. If the switch is pressed toward the ID1
START/STOP jack, you can start and stop the chart drive setting, the four digit ID will appear in the interchannel buffer
without using the front panel controls. When the phone plug has of channel 1. If the switch is pressed toward the ID2 setting, the
been inserted into the REMOTE START/STOP jack, the DASH four digit ID will appear in the interchannel buffer of channel 2.
II is placed into remote start/stop operation. The recorder will 6. Grid Selection Controls
cease running until it receives a switch closure through the
phone plug. The grid selection controls are located directly below the ID1/
ID2 SET switch. The controls consists of a grid ON/OFF switch
4. Power Status Features
above a grid selection switch.
The power status controls and indicators are located in the lower
left corner of the control panel. They consist of the power on/off The ON/OFF switch determines whether or not a grid will be
switch and three LED indicators-CHECK PAPER, LOW BATT, printed on the chart paper.
and POWER. :sl.
The ONE 50 DIV/TWO 50 DIV grid selection switch gives you
When the power switch is in the "on" position (the switch is up), a choice between a single 50-division overlapping grid or two
the green LED labeled POWER is illuminated. 50 division grid channels. When operating in the one-grid
mode, the recorder expands and overlaps the waveforms from
The red LED labeled LOW BATT illuminates to indicate a weak
both signal conditioners on a single grid.
battery condition.
7. Signal Conditioner Card Cage
The yellow LED labeled CHECK PAPER illuminates to alert
you to adjust/refill the thermal paper supply or to ensure that the The DASH II built-in signal conditioner card cage
paper chamber door is completely closed. :esl.
accommodates two ASC-900 series signal conditioners of your
5. System Log Controls choice. (Although they are no longer manufactured, ASC-800
series signal conditioners can also be used with the card cage.)
The System log controls are located in the upper right corner of
the control panel. The controls consists of: :sl.
NOTICE
Four adjacent push-button switches that together form a 4-digit
numeric display. The DASH II will not record waveforms unless signal
conditioners are present and properly installed in the
TIME/DATE SET switch recorder’s built-in card cage.
ID1/ID2 SET switch 8. Marker Controls
The four push-button switches are adjacent to each other and The MARKER controls consist of a manual pushbutton labeled
form a 4-digit numeric display. The display is used in MARK and a four-position rotary TIMER switch. Each of these
conjunction with the ID1/ID2 switch. When the ID1/ID2 controls utilizes the system event marker line to identify data of
control is pushed, this four number display is printed in the interest to you. Don’t confuse the system event marker line with
corresponding interchannel buffer: ID1 for channel one and ID2 the external event marker line. The external event marker line is
for channel two. Each switch of the four number display is always the line printed at the extreme left of the chart paper as
operated by means of two pushbuttons. One pushbutton is above viewed from the recorder’s front.
10-28
The external event marker line is only printed when the The zero-baseline trace can then be easily
external-event phone plug is inserted in the EXTERNAL centered or shifted by rotating the ZERO
EVENT phone jack. When the phone plug is removed, the control knob in the direction of the desired
external event marker line stops being printed. During two-grid left or right shift. When you have
operation, the system event marker line is printed in the positioned the zero baseline, you can
interchannel buffer of channel 2 (near the center of the chart). recover the real-time waveform trace by
During overlap operation, the system event marker line is turning the signal conditioner ON.
printed near the left edge of the chart paper in the interchannel
buffer of channel 1.
GAIN/CAL The GAIN/CAL control functions in two
When you push the MARK pushbutton, the system event ways. When rotated in the GAIN range,
marker line deflects to the left to mark data of interest to you. this potentiometer applies a variable
When you release the MARK pushbutton, the system event fractional gain to the signal on the trace,
marker line returns to its original position. The MARK that is, the GAIN control affects the
pushbutton is only functional when the TIMER SWITCH is set recorded waveform rather than the input
to OFF, the MANUAL pushbutton is disabled. signal. As gain is increased or decreased,
the appearance of the real-time waveform
The TIMER switch is a rotary switch labeled OFF, MANUAL, trace expands or contracts. GAIN
1 SEC, 1 MIN. When this control is used, a timing mark appears approaches its maximum as the
on the system event marker line at the time interval selected: potentiometer is moved toward the CAL
either one second or one minute. The mark is a small, horizontal setting.
spike on the system event marker line.
9. Signal-Adjustment Controls When set to CAL, the switch causes a

precise, factory-set gain to be applied to
The signal-adjustment potentiometers provide real-time the input signal. Because the gain has
waveform trace position controls and signal-strength controls been fixed to a known quantity, each block
for the two recording channels of the DASH II. The controls are of the grid that is printed with the real
labeled CHANNEL 1 and CHANNEL 2. -time waveform takes on precise value
with reference to the attenuator settings
Each channel has two controls placed adjacent to one another: a of the signal conditioners.
ZERO potentiometer and a GAIN potentiometer with a CAL
(calibrated) indent setting.
10. Speed Selection Pushbuttons.
For each channel, the ZERO and GAIN/CAL controls are used
to: :sl. The Speed Selection controls consists of seven pushbutton
speed-selection switches. These pushbutton switches are
• position the real-time trace within the channel rectangular in shape and placed vertically one above another.
They are located along the lower right side of the front panel.
• establish the real-time waveform trace in a calibrated grid The purpose of the speed selection controls is to enable you to
set the speed at which the chart paper will run.
• vary the gain applied to the signal on the trace to expand or
reduce the appearance of the real-time trace (This affects the
recorded waveform rather than the input signal.) The top six switches are labeled in descending order: 100, 50,
25, 10, 5, 1. The numbers indicate the chart speed that will be
ZERO The ZERO control is used to shift the set when the corresponding pushbutton is pressed. The chart
real-time waveform trace of an input speed is the sum of all pushbuttons pressed. A total of 70 speeds
signal to any position within the selected can be obtained ranging from 1 mm/min to 100 mm/sec.
channel. In using this control, you will
probably want to ground the signal as it is
input into the recorder to obtain a When any pushbutton is pressed, it changes to the color orange
fault-line trace. You can do this simply by to indicate that this speed has been selected and is engaged.
turning the signal conditioner OFF for the When pressed, the pushbutton will remain in an indented
particular channel being adjusted. position until it is released by being pressed again.
10-29
The bottom switch in the group is labeled mm/MIN-mm/SEC. 6. Insert the top sheet into the slot beneath the drive roller.
This pushbutton determines whether chart-paper speed will be
set for millimeters per minute (mm/MIN) or millimeters per 7. Manually feed the paper into the recorder and around the
second (mm/SEC). drive roller by carefully pushing the paper forward.
Pressing the switch sets the recorder to operate in the mm/MIN

mode and changes the color of the switch to orange. When the 8. Push the paper forward until it passes over the drive roller and
begins to exit the recorder above the drive roller.
pushbutton has not been pressed and is left in its extended
position, the recorder is set in the mm/SEC mode. In its
extended position, the color of the pushbutton is black. 9. When the paper begins to exit the recorder, evenly pull out
several inches.
11. Chart Paper Chamber
The paper chamber is centered in the lower half of the recorder. 10. Ensure that the chart-paper pack is fully inserted into the
The chamber measures 2-1/2"H x 5"W x 6"D (6.35-cm H x paper chamber by pushing it to the rear of the chamber.
12.7-cm W x 15.24-cm D). The paper chamber door is hinged
at the bottom and provides easy access for paper loading. The 11. Hold the paper lead out of your way and close the paper
chamber accepts Astro-Med thermal Z-fold paper. chamber door. The recorder is now loaded with a pack of
thermal Z-fold chart paper.
Recorder Setup
12. If you have loaded the paper with the recorder turned off,
Before operating your recorder, you must complete all of the turn the recorder on by setting the power switch to the "on"
applicable installation procedures described in section 2, position ("|" showing).
"Hardware Setup." When you have prepared your DASH II for
operation and have familiarized yourself with its connections
and controls, you can prepare the instrument for recording. NOTICE
To prepare for recording: (1) load the recorder with Z-fold If the paper chamber door has not been fully closed,
thermal paper, (2) turn the recorder on, (3) set the time and date the yellow LED indicator, CHECK PAPER, will be il-
luminated.
of the instrument’s internal clock and calendar, and (4) establish
he desired operational setups. Each of these setup procedures is
described below. 13. Push any speed selection button to run the chart paper
briefly. This will ensure that the chart paper is tracking properly.
Loading Z-Fold Thermal Paper

Loading the recorder with a pack of Z-fold thermal paper is Time and Date: Programming the Re-
illustrated in Figure 10-34. The recorder can be either on or off corder’s Internal Clock & Calendar
during the paper loading procedure. Perform the step by step
instructions that follow to insert and position the paper.
The four push-button code switches of the system log group and
1. Remove the Z-fold thermal paper from its box. the TIME/DATE SET switch are used to program the time and
2. Open the paper-chamber door. date of the recorder’s internal clock and calendar. The internal
clock and calendar determine the time and date that appear on
3. Place the paper into the paper chamber making sure that the
the system log and serve as the reference point for all recorder
directions stamped on the Z-wrap are upright and oriented for
normal reading. activities that require time and date data. Remember that the
system log is printed in the channel 1 annotation buffer. This
4. Remove the wrapper from the paper and discard it.
buffer appears on the left side of the chart paper as viewed from
5. Pull the top sheet of the paper pack out of the paper chamber. the recorder’s front.
10-30
Figure 10-34. Loading Recorder with Z-Fold Thermal Paper
10-31
To program the time of the recorder’s in- To program the date on the recorder’s
ternal clock internal calendar
The 4-digit display will read or will reflect the time based on
the last setting of the pushbutton switches. Although you will The 4-digit display will reflect the date based on the last setting
only set the hour and minutes of the internal clock, hours, of the pushbutton switches.
minutes, and seconds will be printed on the system log of the
recorded chart.
1. Press the 4 pushbutton code switches until the correct

1. Press the 4 pushbutton code switches until the correct date (mm/dd) appears in the display.
time is shown in the display.
As the numbers are entered, they are displayed on the four digit Leading zeros must be added when entering a single-digit
dislay. Time must be entered in 24-hour format (hh/mm). month or day. For example, 0420 (April 20).
Leading zeros must be added when entering a single digit hour
or minute. For example, 0332 (3:32 am).
2. Press the TIME/DATE switch toward DATE.

2. Press the TIME/DATE switch toward TIME.
When the switch is pressed, the recorder accepts and retains the When the switch is pressed, the recorder accepts and retains the
data. You can proceed. The time will be printed automatically in data. You may proceed. The date will be printed automatically
the system log during recorder operation. in the system log during recorder operation.
10-32
SECTION 11
PLC LUBRICATION CONTROL
DESCRIPTION Mounted on the enclosure is an audible alarm, three

illuminating pushbutton switches for resetting faults and
A PLC (Programmable Logic Controller) based lubrication starting manual lubricationcycles, one illuminating pushbutton
control system has been developed by Harnischfeger for silencing the audible alarm and an ALLEN-BRADLEY
Corporation for use on mining excavators. This control was TCAT timer/counter control for monitoring or changing the
designed to replace existing Lincoln or Farval controls. It is lube cycle or fault timers.
available as a complete system including new solenoid valves,
pressure switches , flow control valves and pressure regulators
as part number 100A14733F1 for older models or as standard
equipment on new excavators with part number 100A13836F2.
The optional remote station, part number 100A13838F1,
The system is comprised of a 20” X 24” Nema 12 enclosure contains an audible alarm and three illuminating pushbutton
with an ALLEN-BRADLET SLC-150 programmable switches which duplicate the functions of their counterparts on
controller, isolation transformer, thermostat, heater elements, the controller cabinet door. On later machines, this remote
electronic time delay relay, power relay and terminal strip. All station is incorporated in the left hand console pushbuttons. The
external connections made to the terminal strip in the cabinet. procedures for use however, are the same.
5 1a 1b
11
4
10 7
12 9 8 2
Figure 11-1. SLC-150 Programmable Controller
11-1
SLC-150 PROGRAMMABLE 9. EEPROM MEMORY MODULE COMPARTMENT
CONTROLLER 10. COMMUNICATION PORT.
The Allen Bradley SLC-150 programmable controller has 20 11. EXPANSION UNIT CONNECTION.
inputs and 12 outputs. As shown below, these inputs and outputs
12. BATTERY COMPARTMENT.
are terminal strips on either side of the controller and are clearly
identified as to their purpose:
DESCRIPTION OF OPERATION
1a.Incoming line terminals.
Temperature Control
1b. Wiring terminals for 20 inputs.
Two heaters and an associated thermostat maintain proper
operating temperature for the SLC-150.
2. Wiring terminals for 12 outputs.
3. Color patch. NOTICE

It is recommended that the thermostat be set at 40°-
4. DIAGNOSTIC INDICATORS: These “LEDS” are basic 45° F (4° - 7° C).
function indicators.
If power is removed from the shovel and the temperature is
A. DC POWER: Indicates that the processor unit is below that required (32° F, 0° C), lube operation is inhibited
energized and DC power is being supplied. until the proper temperature is reached (up to a maximum of 30
minutes). If the proper temperature is not reache within 30
minutes, a continuous audible alarm (warble) will be activated.
B. PC RUN: Indicates processor is in the run mode. This same alarm will sound if for some reason during operation
there is a SLC-150 controller failure.
C. CPU FAULT: Indicates the processor has detected an
error in either the CPU or memory. Operation is
automatically stopped.
NOTICE
1. If the controller is connected per instructions, the
D. BATTERY LOW: Indicates when battery voltage level cabinet temperature is maintained anytime power is
has dropped below a threshold level. applied to the shovel and the proper breakers are
closed.
E. FORCED I/O: Indicates that one or more input or output
addresses have been forced to an ON or OFF state. 2. In extremely cold climates (below -30° F, -34° C), it
may take longer than 30 minutes for the cabinet to
reach operating temperature after an extended power
6. INPUT STATUS INDICATORS: Twenty red LEDS, outage. This will cause the system to go into alarm.
identified with address numbers 1 through 16, 111 through 116,
corresponding to numbers on the output contact wiring 3. Resetting a low temperature or PLC failure alarm
terminals. When a programmed input circuit is energized, the necessitates cycling the power to the lube controller of
corresponding status indicator will be lit. and on.
7. OUTPUT STATUS INDICATORS: Twelve red LEDS, Pushbutton Indicators

identified with address numbers 11 though 16, 111 through 116,
corresponding to numbers on the output contact wiring The illuminating pushbuttons perform multiple functions. Upon
terminals. When a programmed output instruction is TRUE, the machine start-up, all lights should flash in sequence, indicating
corresponding output status indicator will be lit and the start-up and doubling as lamp test function. During normal
corresponding output circuit will be energized. operation, the lights will illuminate when their respective lube
pump is operating. Should a fault occur, the light will flash and
8. AUTO/MANUAL SWITCH: This switch controls start-up of an audible alarm will sound. The fault can be reset and a manual
the processor after a power loss. lube cycle initiated by depressing the reset/manual pushbutton.
11-2
A manual lube cycle can be initioated any time power is applied Processor Memory:
to the shovel and the controller is energized (machine started or
not).
The SLC-150 processor used in the Harnishfeger Lube
Controller has a CMOS RAM type memory. This memory
requires a continuous voltage source to maintain the program in
Alarms: memory. For utmost reliability, this controller is supplied with
three types of memory backup.
A lubrication fault initiates an audible alarm which alternates 1. The SLC-150 comes with a “capacitor backup” as a standard
feature. This charged capoacitor will provide memory backup
between a “warble” and a “yeow”. As previously stated, a fault
for one week after power has been removed from the unit,
can be reset and a manual lube cycle initiated by depressing the without any other backup source.
appropriate pushbutton.However, if the the fault condition still
exists, the alarm will again sound when the fault timer 2. Battery backup is provided in the form of a lithium battery
completes its cycle. The audible lube fault alarm can be silenced which resides within the SLC-150. This non-rechargeable
by depressing the ALARM SILENCE pushbutton. This, battery will provide memory backup for approximately two
years, although replacing the battery after one year is
however, will not stop the flashing light indicator, which
recommended.
indicates the system is at fault. This feature allows system
troubleshooting without the audible alarm interfering. After the 3. For ultimate security, an EEPROM memory module is
fault is corrected, the fault indications can be cleared and the provided. The EEPROM is a nonvolatile memory, meaning that
alarms re-armed by depressing the appropriate manual/reset it requires no battery backup to retain its contents. The
pushbutton. EEPROM is factory programmed and will not accept field
adjustments; therefore, unless the factory programmed cycle
times fill your needs, the EEPROM is not normally plugged into
the processor. It is stored in the lube controller cabinet and is
As mentioned in the Temperature Control section of the manual, only used in the unlikely event that the processor memory is
a low temperature or PLC failure alarm (steady “warble”) must lost. Should such an event occur, the battery should be replaced,
be reset by cycling the controller power off and on. and with the power off, the EEPROM should be inserted in the
processor. When power is reapplied, the contents of the
EEPROM will automatically be loaded in the processor ram.
Power can then be removed and the EEPROM removed again.
Lube Cycles: In the event that cycle times other than the factory programmed
times are required, you must re-enter them at this time.
The lube cycle intervals are feild adjustable in one second

increments using the TCAT timer/counter control mounted on LUBE CONTROL INSTALLATION
the front of the system enclosure. As a lube conservation
feature, lubrication cycles are only initiated when the machine
Electrical Connections
is actually in operation (digging or propelling). If the machine
is “started” but sitting idle (brakes set), cycle timers are
inhibited until the brakes are released. Lube intervals are
! WARNING
DANGER
independent of machine start/stop times. If a 22 minute cycle
time is programmed, and the shovel is shut down 12 minutes High voltage can cause severe injury or death. Pri-
into the cycle, the next lubrication cycle will not take place until or to installation, ensure that ALL circuit breakers
supplying power to the lube system and associated
10 minutes after the machine is started and in production. A
inputs are OPEN.
saftey feature is programmed into the control which will
override the set time with a factory predetermined maximum
All electrical connections are made to the terminal strip at the
cycle time to ensure proper lubrication. A minimum cycle time bottom of the controller cabinet. Use external wiring schematics
is also incorporated to ensure enough time for the system to (Figure 11-2) and wiring schedule (Table 11-2) to determine the
releive pressure between cycles. proper connections.
11-3
Figure 11-2. External Wiring Schematics
11-4
START-UP
NOTICE
To avoid damage to the PLC or associated lube system
components, it is very important that EVERY INPUT When wiring is complete and power is applied to terminals 1
AND OUTPUT be referenced to the SAME 120 VAC (hot) and 2 (common), it is only necessary to close the internal
COMMON regardless of whether the common is ma- circuitbreaker switch to activate the controller.
chinery house ground (agnd or 1021) or one phase of a
3-phase 120VAC circuit (i.e. E33).
This control is programmed to operate with either LINCOLN or NOTICE

FARVAL lubrication systems. 1. It is normal for the controller to momentarily go into
“alarm” upon applying power.
LINCOLN: Pressure Switch connections are made to
terminals 8, 9, 10 and 11. 2. If the ambient temperature e controller cabinet is be-
low that required (be sure the thermostat is set to 40-45
degrees F (4-7 degrees C) the PLC will remain “OFF”
FARVAL: Reversing valve switch connections are made to until the internal cabinet heaters sufficiently warm the
terminals 12 through 17 and terminal 30. cabinet. Check to see that the “ON” indicator is illumi-
nated on the delay relay and the heaters are function-
ing.
There are two (2) input terminals for the hoist brake solenoid
signal. ONLY one input will be used on any machine. 3. When the cabinet is up to temperature and power is
applied, the TCAT display will be “on”.
1. Use terminal 29 if the hoist brake solenoid is hard wired to
the “HOT” 120VAC lead and the “COMMON” side is switched.
2. Use terminal 32 if the hoist brake solenoid is hardwired to the

Cycle Timers
“COMMON” 120VAC lead and the “HOT” side is switched. If
terminal 32 is used, you must jumper input 29 to either terminal
28 or31 (common). There are four programmed timers associated with each of the
individual lube “systems” (upper, lower, open gear and propel).
These timers and their functions are as follows:
NOTICE
Refer to the machine schematics to determine which
MAXIMUM INTERVAL TIMERS. This is a factory preset
terminal to use.
timer which limits the maximum lube interval to 40 minutes for
the upper, lower and open gear lube systems and 3 minutes for
The optional remote station 100A13838F1, if used, is the propel system. This timer is not field adjustable.
connected to terminals 5 though 7, 18 through 22 and terminal
11. Wire per color code shown in Figure 11-2. Open
Timer Upper Lower Gear Propel
Maximum
NOTICE Interval 915 918 922 919
Minimum
If this control is replacing a two timer system, the un- Interval 916 920 923 914
used section (upper, lower and open gear) must have its
LINCOLN pressure switch input (terminal 8, 9 or 10) Normal
Cycle 910 911 913 912
jumpered to terminal 11 to eliminate fault indications
and alarms associated with the unused section. Jumper Fault 917 921 924 921
the unused LINCOLN input regardless of whether
your system is LINCOLN or FARVAL. Table 11-1. PLC Timer Addresses
11-5
Typical 2300
Term. Input Remote 1900 2300 2800 2300XP 2300XPA
No. Output Signal Description Station 2100 2800 (AGND) 2100BLE 2800XP 2800XPA
1. I 120 VAC (HOT) E22 HC1 ALDB ALDB 25261 25261
2. I 120 VAC (COMMON) E33 HC2 AGND AGND 1021 1021
3. I “Start” E2 H1P H1P H1P 26351 26351
4. I “Propel” E6 (T6) AL3 AL3 AL3 26371 26371
5. I Upper Man/Reset Remote (red)
6. I Lower Man/Reset Remote (orange)
7. I Open Gear Man/Reset Remote (blue)
8. I Lincoln Upper Pressure Switch
9. I Lincoln Lower Pressure Switch
10. I Lincoln Open Gear Pressure Switch
11. O 120 VAC “HOT” (black)
12. I Farval Upper (NO)
13. I Farval Upper (NC)
14. I Farval Lower (NO)
15. Farval Lower (NC)
16. I Farval Open Gear (NO)
17. I Farval Open Gear (NC)
18. O Remote Alarm (brown)
19. O Upper Indication / Remote (yellow)
20. O Lower Indication / Remote (violet)
21. O Open Gear Indication / Remote (gray)
22. O 120 VAC “common” (white)
23. O Upper Lube Pump Solenoid
24. O Lower Lube Pump Solenoid
25. O 120 VAC “common”
26. O Open Gear Lube Pump Solenoid
27. O Lube Air Spray Solenoid
28. O 120 VAC “common”
29. I Hoist Brake Solenoid** HBS HBS**
30. O 120 VAC “hot”
31 O 120 VAC “common”
32 I Hoist Brake Solenoid HB1 HBS** HBS 32133 51041
33 O Air Compressor Drain Solenoid 26401
Table 11-2. External Wiring Schedule
11-6
MINIMUM INTERVAL TIMER. This is a factory preset timer CHECKING PRESET TIMES. Lube cycle times can be
which limits the minimum lube interval to 2 minutes for the checked at anytime (machine running or not) as follows:
upper, lower, and open gear lube systems and to 30 seconds for
the propel system. This is to ensure that the lube systems have 1. Select the MONITOR key switch position.
sufficient time to relieve pressure between pump cycles. This
timer is not field adjustable. 2. Press the ADDRESS pushbutton once.
3. Load the last two (2) digits of the counter address.

NOTICE
Upper Lube = 9 10
In cold climates, 30 seconds may not be long enough
for the propel system injectors on LINCOLN type sys-
tems to relieve pressure. Observe your propel lube in- Lower Lube = 9 11
jectors; if they are not completely resetting, adjust
your normal cycle timer for a longer interval. The min- Propel = 9 12
imum interval timers are not field adjustable.
Open Gear Lube = 9 13
NORMAL CYCLE TIMER. This timer may be adjusted in the
field and will provide the desired lubrication intervals based on 4. Press ENTER.
your shovel’s operating conditions. As recieved from the
factory, the upper, lower and open gear lube system timers are 5. Press PRESET once.
set for 15 minute cycle intervals and the propel timer is set for a
3 minute interval. 6. The time displayed is the lube interval in seconds.
This timer is field adjustable to any desired time between the MONITORING TIMER ACTION. To monitor a lube counter
maximum and minimum interval timers. during a lube cycle, proceed as follows:
1. Select the MONITOR key switch position.

FAULT TIMERS> This timer sets the maximum lube pump
running time which will be accepted before a lube fault alarm is
2. Press ADDRESS once.
initiated and the system (i.e. upper, lower or open gear) shuts
itself down. As recieved from the factory, this timer is set for 3. Load the last two digits of the counter address.
three minutes, but is field adjustable should a different fault
time be desired. 4. Press ENTER.
AIR COMPRESSOR DRAIN TIMER. 100A13836F2 5. Press ACCUM once.

controllers have an additional timer used to control the air
compressor drain solenoid. This timer is at address 926 and is 6. If the machine is operating, the counter will be counting up to
factory set for one hour intervals, but is field adjustable. At each the preset level, then resetting and starting again. If the machine
cycle interval, the air compressor drain solenoid is held open for is not operating, the number of seconds accumulated up to the
a period of three seconds. point that the machine stopped operating will be displayed.
TIMER ADDRESS. The timer addresses which may be used to

monitor or modify these timers are shown in Table 11-1. Please NOTICE
note that maximum interval or minimum interval timers may 1. With the key switch in the MONITOR position, it is
not be changed at any time. not possible to change the cycle times.
2. With the key switch in the MODIFY position, cycle

Setting Cycle Times times may be changed.
Use the LUBE CYCLE PROGRAMMING instructions found 3. It is not possible to alter the program or change the
on page 11-8 to adjust the lubrication intervals and fault timers factory preset minimum or maximum setpoints in ei-
using the TCAT Timer/Counter control. ther key position.
11-7
Lube Cycle Time Programming they are tight. Keep the cabinet and equipment clean, but avoid
using strong solvents.
Upper Lube Cycle Time . . . . . . . . . . . . . . . . . . . . .Address 910
Lower Lube Cycle Time. . . . . . . . . . . . . . . . . . . . .Address 911
Propel Lube Cycle Time. . . . . . . . . . . . . . . . . . . . .Address 912
Processor unit - SLC-150
Open Gear Lube Cycle Time . . . . . . . . . . . . . . . . .Address 913
Air Compressor Drain Cycle . . . . . . . . . . . . . . . . .Address 926 BATTERY REPLACEMENT. The battery can be replaced
without disconnecting power or disturbing normal operation of
All times are in seconds (i.e. 300 = 5 minutes). To change a the shovel using the following procedure.
cycle time, refer to the address list above and proceed as
follows. 1. Remove the battery compartment door from the front of the
processor unit.
1. Select the MODIFY position with the keyswitch.
2. Press ADDRESS once. 2. Remove the battery assembly stored in the compartment as
follows.
3. Load the last two (2) digits of the counter address.
A. Pull up on the lead wires and remove them from the
4. Press ENTER.
compartment.
5. Press PRESET once to display the present time setting and a
second time to load a new time. B. Remove the battery from the small retainer clip in the battery
compartment by applying pressure to the left side of the
6. Load the new time in seconds. battery with a small screwdriver or similar tool while
pulling up on the lead wires.
7. Press ENTER.
8. Press ACCUM twice. C. Unplug the female end of the connector.
9. Press ENTER. 3. Connect a new battery, making sure the slot on the battery is
10. Return the keyswitch to the MONITOR position. aligned with the key on the socket.
See the TCAT USER’S MANUAL for additional information. 4. Insert the battery into the battery compartment minus side
first (white lead wire). Push the retainer clip to one side with the
battery so that the battery will fall to the bottom of the
MAINTENANCE compartment and be held in place by the clip.
The P&H Lubrication Controller requires very little 5. Place the battery connector and lead wires in the
maintenance. As with any peice of electrical equipmenty compartment.
working in harsh environments, it is a good practice to
periodically check all electrical connections to make sure that 6. Replace the compartment door.
11-8
EEPROM Memory Module Installation
NOTICE
NOTICE Restoring power to the processor with the EEPROM
installed loads the contents of its memory into the pro-
Always turn off power to the processor before you in- cessors CMOS RAM. As discussed under the PRO-
sert or remove the EEPROM. This guards against pos- CESSOR MEMORY topic on page 11-3, operating the
sible damege to the EEPROM and also avoids lube controller with the the EEPROM installed is not
undesired CPU faults. advised.
INSTALLATION PROCEDURE. To install the EEPROM into

the processor, proceed as follows:
5. Remove power from the processor.
1. Turn off power to the processor unit .
2. To insert the memory module, remove the cover from the
front of the processor unit. Save the cover for use later. 6. Remove the EEPROM from the processor and save it for
future use.
3. Align the memory module socket with the recepticle inside
the processor unit. Push carefully to seat the module.
4. Restore power to the module. 7. Replace the memory module socket cover.
11-9
11-10
11-11
11-12
11-13
QUANTITY
RE
PART NUMBER DESCRIPTION FIGURE
F
1
-- PUSHBUTTON STATION, LUBE CONTROL
01 .ENCLOSURE, Pushbutton
02 .NAMEPLATE, "Lube"
FOR PART NUMBERS
SEE PARTS MANUAL
03 .ALARM, Audible
04 .NAMEPLATE, "Upper"
05 .PUSHBUTTON ASSEMBLY, w/Red Lens
06 .NAMEPLATE, "Lower"
07 .NAMEPLATE, "Open Gear"
08 .GRIP, Cord
09 .LOCK NUT, Conduit 1/2 in
10 .CABLE, 10 Conductor #18AWG
11 .BLOCK, Contact
Figure 11-3. Optional Remote Station (See Following Page for Descriptions)
11-14
Figure 11-4. PLC Lubrication Controller (See following Page for Descriptions)
11-15
QUANTITY
RE
F
2
-- PUSHBUTTON STATION, LUBE CONTROL
01 .SCREW, Hex Hd Cap 1/4-20UNC x 3/4 in
02 .WASHER, Lock 1/4 in
03 .WASHER, Plain 1/4 in
04 .GUARD, Heater
05 .HEATER, 200 Watt
06 .RCV
07 .WASHER, Plain #6
08 .WASHER, Lock #6
09 .SCREW, Rd Hd Mach #6-32UNC x 1/2 in
10 .ALARM, Audible
11 .NIPPLE, Close 1/2 in
FOR PART NUMBERS
SEE PARTS MANUAL
12 .WASHER, Reducing - Conduit 3/4 to 1/2 in

13 .ENCLOSURE
14 .THERMOSTAT
15 .BUSHING, End - Conduit 1/2 in
16 .END BUSHING, Conduit 1/2 in
17 .TRANSFORMER
18 .HEATER, 150 Watt
19 .BREAKER, Circuit
20 .BRACKET, Circuit Breaker
21 .NAMEPLATE, "ON/OFF"
22 .SOCKET, Relay
23 .RELAY
24 .SPRING, Relay Hold Down
25 .TERMINAL, TCat
26 .NAMEPLATE, "Open Gear Lube-Manual/Reset"
27 .NAMEPLATE, "Lower Grease-Manual/Reset"
28 .NAMEPLATE, "Upper Grease-Manual/Reset"
29 .NAMEPLATE, "Alarm Silence"
11-16
QUANTITY
RE
F
2
30 .NAMEPLATE, "Lube Control-100A13836F2"
31 .PUSHBUTTON, Lighted
32 .REED CONTACT, NO /N C
33 .STRIP, Marking
34 .BLOCK, Terminal
35 .SECTION, End
FOR PART NUMBERS
SEE PARTS MANUAL
36 .STOP, End
37 .RELAY, Time
38 .SOCKET, Relay
39 .CLIPS, End
40 .RAIL, Mounting
41 .PROCESSOR, PLC
42 .MODULE, Memory
43 .BATTERY
44 .SCREW, Rd Hd Mach #10-32UNC x 1/2 in
45 .WASHER, Lock #10
46 .DUCT, Wire 40 in
47 .LOCKNUT, Conduit 1/2 in
48 .WASHER, Plain 7/8 in
11-17
SECTION 12
PROPER MOUNTING AND TESTING OF POWER SEMI-
CONDUCTORS a thyristor or diode, the threads of the clamp bolts

should be coated with silicone grease.
GENERAL Assembly
This section covers the procedures to be used when removing or 1. Check that the mating surface between the thyristor and heat
installing power semi-conductors. The advantage of the disc sink are clean and free from scratches, etc.
type power semi-conductor is the improved heat transfer 2. Sparingly apply a thin film of electrical/thermal joint
characteristics in double side cooling applications. The larger compound (Part Number 21Z808) to the semi-conductor
flat anode and cathode surfaces provide two direction heat flow mounting surfaces. The application of thermal compound
paths which allow approximately 60% more power dissipation serves two functions. It serves to resist corrosion and it
at the same device junction temperature than the stud mounted enhances the mating surfaces by filling the microscopic voids
type of thyristor. with a more thermally conductive material than air.
REMOVAL AND INSTALLATION NOTICE

To insure proper operation and performance of the power semi- Excessive amounts of joint compound may be detri-
conductor, the following precautions must be taken during mental to proper performance due to increased thermal
disassembly and installation. resistance.
3. Before installing the new device into the heat sinks, it should
Disassembly be tested using the Thyristor Tester 89Z511. Operation of the
tester is described in section 10.
1. Remove all mounting brackets from the thyristor or diode
heat sink assembly. Disconnect the gate-cathode leads from the 4. Install the new device between the heat sink halves, making
pulse transformer. sure it is properly centered.
2. Place the heat sink assembly on a flat surface, noting the 5. Tighten the thyristor clamp nuts finger tight and check that
cathode and anode of the device as well as the gate cathode the spring bar is parallel to the heat sink.
leads with respect to the mounting clamp. Make sure the 6. Check that the assembly is properly aligned and that the ends
assembly is reassembled in the same configuration (see Figure of the heat sink sets squarely on the flat surface.
12-1).
7. Tighten the clamp nuts alternately 1/4 turn at a time to the
3. Loosen the clamp by alternately loosening the clamp nuts in total specified turns for each nut to insure proper clamping force
1/4 turn increments. (see Table 12-1 ).
4. Remove the thyristor.
Installation
NOTICE 1. Place the heat sink/thyristor assembly in the proper location
Three types of thyristor clamping assemblies are used
2. Start all mounting bolts before tightening.
on the MkII Electrotorque Systems. Whenever the
clamp assemblies are removed for the replacement of 3. Tighten the mounting bolts.
12-1
Cathode Cathode Lead
(Red Wire)
Gate Lead
Anode (White Wire)
Thyrister Assembly
Heatsinks
Thyrister
Nuts
Clamp
Figure 12-1. Thyristor Assembly
12-2
Table 12-1. Thyristor Clamping Force
DESCRIPTION PART NUMBER FORCE-LBS TURNS

DIODE 75Q68D1, D3 1875 1
DIODE 75Q68D2 2600 3/4
DIODE 75Z935D1 2600 3/4
THYRISTOR 79Q58D60 1375 3/4
THYRISTOR 79Q58D68 1375 3/4
THYRISTOR 75Z727D7, D8, D9, D13 4750 1-1/8
THYRISTOR 75Z727D14 9500 1-1/4
4. Connect the gate leads to the proper terminals.
Testing Power Semi-Conductors

In order to test the armature, field, RPC or diverter semi-
conductors while the device is still mounted in the machine, the
following procedure should be followed:
! WARNING
DANGER
Make sure all systems are shut down and all circuit
breakers are set to their OPEN positions.
1. Open the armature circuit breakers.

Figure 12-2. Typical dv/dt Network
2. An ohmmeter can be used to quickly identify a shorted
device. The ohmmeter will read zero ohms when connected
across a shorted device. Only one side of the dv/dt circuit need be opened, but it is
important to open all of the networks even though only one or
3. If it is suspected that a device is not gating properly or is two devices may be checked. This is because one forward
breaking down with the applied voltage, the thyristor tester device is always in parallel with a reverse device. For this
must be used to test each device for given parameters. The reason, the forward and reverse leakage current values may be
operation of the thyristor tester and device parameters are slightly higher than if the device was "bench tested"
described in section 10.
4. When checking armature thyristors, it is necessary to remove

all of the dv/dt wiring on each of the devices in the bridge
containing the suspected device. The dv/dt circuitry consists of
resistors and capacitors that are wired in parallel with each
device (see Figure 12-2).
12-3
APPENDIX
INSTRUMENT RECOMMEND ALTERNATE
DIGITAL MULTIMETER FLUKE, MODEL 23 FLUKE, MODEL 8062A
PART NO. 89Z514D12 PART NUMBER 89Z514D7
TONG TESTER COLUMBIA ELECTRIC
TYPE AX
(CLAMP-ON AMMETER) W/CURRENT RANGES:
50, 200, 500, 1000 AMP.
PART NUMBER 89Z367
MEGGER JAMES G. BIDDLE
CATALOG NUMBER 21158
HAND OPERATION W/CASE
PART NUMBER 89Z496
OSCILLOSCOPE FLUKE, MODEL 97 TEKTRONIX, MODEL 214
PART NUMBER 89Z138D1 PART NUMBER 89Z515D4
ISOLATION TRANSFORMER 115VAC PRI/115VAC SEC
50/60 HZ. 250VA.
PART NUMBER 75Z820D1
CHART RECORDER ASTRO-MED, DASH 2MT BRUSH, MODEL 220
50/60 HZ. (60 HZ) PART NUMBER 89Z471
PART NUMBER 89Z835D1 (50 HZ) PART NUMBER 89Z472
START-UP RESISTOR 2000 OHM, 6000 WATTS
REFERENCE/PUSHBUTTON PART NUMBER 89Z833D1
UNIT
RPC/STEP REFERENCE UNIT PART NUMBER 89Z866
CAPACITOR UNIT PART NUMBER 89Z508D1
VOLTAGE DIVIDER PART NUMBER 89Z510D1 89Z869 Small v Divider
Fb SIMULATOR (OPT.) PART NUMBER 89Z654D2
PLC TERMINAL ALLEN BRADLEY, T45
INTERFACE CABLE ICOM, C-18
(PLC 2) PART NUMBER 79Z4937D5
SOFTWARE ICOM, L2-300
(PLC 2) 3.5 INCH PART NUMBER 79Z4937D3
INTERFACE CABLE ICOM, C-19
(PLC 5) PART NUMBER 79Z4923D6
SOFTWARE ICOM, L5-300
(PLC 5) 3.5 INCH PART NUMBER 79Z4923D5
RS232 TO RS422 CONVERTER PART NUMBER 89Z139D1
DATA LOGGING SOFTWARE FOR UTICOR
PMD
12-4
MODELS 2300XPB, 2800XPB, 4100 & 4100A READER
ELECTROTORQUE TROUBLESHOOTING GUIDE COMMENT
CATALOG 305-1 FORM
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whatever information you supply in any way it believes appropriate without any obligation to you. All comments and sugges-
tions are both welcome and appreciated.
Please do not use this form to report machine problems or to request additional publications. Machine problems should be
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addressed to the Technical Publications Department.
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P&H Mining Equipment
Copyright © 1997 Harnischfeger Corporation, Milwaukee, Wisconsin 53201
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ELECTROTORQUE® TROUBLESHOOTING GUIDE

MODELS 2300XPB, 2800XPB, 4100, & 4100A

JUNE 15, 1998

TC CAT 305-2 VER 00, 06-98

All rights reserved. Printed in the United States.

Section 1 …………… General Information

Harnischfeger Institute-Technical Communications P&H® Mining Equipment

North York Chile

Harnischfeger Institute-Technical Communications P&H® Mining Equipment

Beijing P&H MinePro Electrical Services

Harnischfeger Institute-Technical Communications P&H® Mining Equipment

Practices for Mining Equipment Users

Preface 1. Appointed qualified operators, who have met the

Mine Management's Responsibility

He must be alert, physically fit, and free from the influences of

Operating Instructions 10. Leaving a shovel or excavator unattended can be very

• Severe reduction of rope diameter or an observable increase in

• Evidence of severe corrosion, particularly in the vicinity of

• A rapid increase in the number of broken wires.

INTRODUCTION di/dt - The rate of change of current with respect to time.

Figure 1-8. Astable Elements

Figure 1-6. Bistable Element (Continued) Figure 1-9. Delay Elements

Figure 1-11. Amplifier Circuits Figure 1-12. Amplifier Circuits (Continued)

Figure 1-14. Other Symbols

Figure 1-15. Model 2300XPB Equipment Locations

TRANSFER CONVERTER FIELD BREAKER 480 VAC AUXILIARIES

Figure 1-16. Model 2800XPB and 4100 Equipment Locations

TRANSFER CONVERTER DIPPER TRIP 480 VAC

Figure 1-17. Model 4100A Equipment Locations

GENERAL 5. SWING BRAKE SET BUTTON. Depressing the brake set

01. CONTROL CONSOLES 21. DC MOTOR OVERLOAD INDICATOR

Figure 2-1. Operator Control Locations - Model 4100

9. SWING BRAKES RELEASE INDICATOR/

Figure 2-2. Operator’s Controls - Raised Control Console Panels

35. SWITCH, DIMMER. This switch is used to control the

METER MODULE OPERATION

GENERAL METER SELECTOR SWITCH

Figure 3-1. Meter Module

2. When the Test Selector switch is in the ARMATURE TEST

3. The CONTROL TEST position allows various measurements

4. The AUXILIARIES TEST position will permit operation of

TEST SELECTOR SWITCH

The position of the Test Selector switch determines which mode

2. The meter in the center indicates values of motor armature

A. It indicates armature voltage.

B. It indicates control voltage and test voltage values.

Because the common lead to the meters is connected internally

The 600-0-600 volt scale is used to monitor armature motor

The 12-0-12 volt scale is used when making measurements of

The 30-0-30 volt scale can also be used to monitor any DC

When the METER SELECTOR switch is in the 3 volt test

1. Turn the relay supply and control supply circuit breakers to

2. Set the toggle switch to the UP or ORANGE position.

3. Set the METER SELECTOR switch to the +24 volt control

4. Set the METER SELECTOR switch to the -24 volt control

5. Set the toggle switch to the down or yellow position.

TROUBLESHOOTING WITH THE PLC-5/15 FAULT

Table 4-1. Index - Rack 3 Indicator Lights

ADDRESS IDENTIFICATION PAGE

030-00 Ground fault main transformer Page 4-10